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^.•^.•*/ *^^'T?^\/ %*^-'/ .. %'^' 






Foundry 

Moulding Machines and 

Pattern Equipment 



A TREATISE 

SHOWING THE PROGRESS 

MADE BY THE FOUNDRIES USING 

MACHINE MOULDING 

METHODS 



By 

EDWIN S. CARMAN, 

Mechanical Engineer 

Mem. Amer. Soc. M. E. 
Mem. Cleveland Eng. Soc. 



SECOND EDITION 

ILLUSTRATED 




t>^ 



■^> 



C O P Y R I G II T 

In the United States and Canada, 1020 

Entered at Stationer's Hall, London, by 

EDWIN S. CARMAX, Clevlland, 6. 

.■ill rights resenrd 



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FEB a I 1921 
0)CU60843o 



INTRODUCTION 

During the past years marvelous advances have be.-n made 
in the amount of production obtained from the daily efiforts 
of man. This is true not only in the industrial establish- 
ments, but it is true in practically all walks of life, and 
especially does this fact stand forth in our home life, 
transportation, trucking, farming, merchandising and in the 
industrial arts; it is evident in the steel mills, machine shops, 
pattern shops and in some few foundries, especially those 
foundries engaged in the manufacture of automobile cast- 
ings. The increased production that is obtainable in these 
and in many other lines of daily activities, has been brought 
about by the utilization and application of scientific knowl- 
edge, engineering principles and mechanical appliances. 

This is a mechanical age. The hard, drudging, physical 
effort is being taken out of labor. Labor is now, in nearly 
all instances, being performed by the pulling of a lever, or 
the pressing of a button. The farmer's life is easy, plowing 
is performed by power, the wheelbarrow has become a truck, 
the Japanese jinrikisha an automobile, the hammer and 
chisel are replaced by lathe and planer; but to the foundry 
in general these contrasts will not apply, as the moulding 
in some plants is still being performed in the same manner 
as it has been for centuries past. The mould is still made 
in the old-style wood flask, hand rammed by the same old 
laborious method, and very little accomplished at the day's 
close. Instead of being fresh and vigorous, the man is 
exhausted, the production small, and in many cases the 
castings defective. 

A new day is upon us. It is here ; we cannot change 
it ; regardless of our individual attitude, it is here to stay ; 
we cannot even delay its workings ; we must launch out into 
the current of modern activities, or the current will strand 
us upon the reef. Our individual effort will be judged 
by the amount of work produced. There will be no place 
for the man who is willing to work through a long, hard 
day of drudgery in order to perform his daily work, but 



IV Foundry Moulding Machines and PatUrn Equipment 

instead, he wlio can produce as his day's work, maximum 
production with a mininuun of effort, will be the one who 
stands the liighest. 

The manufacturers today are not desirous of obtaining 
a maximum production by means of exacting hard hours 
of labor, but instead, in the great majority of industries, 
the maximum production is obtained by mechanical means, 
witii minimum labor. The foundry has been one of the 
last industries to adopt mechanical means of saving hard, 
drudging labor, and the very fact of its being late in start- 
ing is perhaps the reason for the rapid development that 
has been made. 

Further progress will iiave been made when mord 
attention has been given by engineers to detail casting design 
in order to meet the foundry's requirements as to moulding 
methods, and by the manufacturer when ordering or having 
made patterns that are to be used by ihe foundry. 

It is with a view to stimulating cooperation between 
foundrymen. manufacturers and engineers that this book 
is written, i heir working together will be the means of 
producuig the world's ever increasing casting suj^plv in an 
easier and better way. The author, believing that pictures are 
of great value in the presentation of ideas, has endeavored, by 
a very liberal use of engravings, to illustrate the method of 
mounting patterns and the making of moulds l)v machine power. 
An endeavor has been made in this book to explain tlie diffcM- 
ent types of moulding machines together with the pattern and 
flask equipment necessary for their use. in such a wav that 
the reader will obtain a grouj) of fundamental conceptions in 
regard to machine moulding that will be of value to him in 
any line of engineering work in the foundry, and that the 
practical foundry man will ha\e liglit shed on that most impor- 
tant f|uestii)n, "Will it he jjrohtable to run this job on a 
moulding machine, and if so. on what tvpe of machine?" 

Chapter 1 contains much th;it is elementary in nature and 
will be of benefit to those who are not familiar with foundry 
terms. The practical foundryman may feel inclined to skip the 



Introduction 



olcnientarv mattt-r. but he should lake care not to skip the state- 
ments of tun(huiuMUal importance in rej^ard to machine mould- 
ing. 

With ad\ances coming so rapidly, the best j)ractice of today 
becomes antiquated tomorrow and it is with a full realization of 
this fact that some of these methods of producing castings are 
here shown. They may be obsolete before the book reaches 
the reader. Ilowever. a study of the methods given in this 
book will atiford to the reader an insight into the process of 
making moulds by machine jxnver. and if vie\\ed in this light, 
the truths set forth are (|m'te universal. 

1-Jnvi.\ S. C.XRMAN. 

Cleveland, Ohio, November, 1920. 



VI Introduction 



Preface to the Second Edition 

The lirst edition was. as far as the writer is informed, the 
first attempt of an author to publish a work covering the sub- 
ject of machine moulding. It was felt, however, that the first 
edition did not sufficiently cover all of the many details and 
ramifications of the art of machine moulding, and therefore, in 
the second edition such details are covered more completely. 

Investigation has shown that many of our colleges, insti- 
tutes and technical and trade schools desire to give to the stu- 
dent a training in up-to-date foundry methods but are unable 
to do so because of a lack of sufticient data on hand with which 
properly to prepare a thorough course of study, and it is with 
a view to supplying these needs that Chapter I has been added. 
This chapter treats the fundamentals of machine moulding, 
being both elementary and advanced theory and practice. 

The book will also be appreciated by those in the industry 
who are desirous of changing their methods from hand to 
machine moulding; also by the manufacturer w^ho is desirous 
of having his organization furnished with a complete treatise 
which shows in detail the methods of pattern mounting and 
machine moulding. 

Edwin S. Carman. 

Cleveland. Ohio, November, 1920. 



Table of Contents VII 

Table of Contents 

CHAPTER PAGE 

I General Moulding Principles 1 

II The Theory of Jolt Ramming 31 

III Roll Over Jolt Moulding Machines 40 

IV Roll Over Jolt Moulding Machines for Large Size Moulds 58 

V Roll Over Jolt Machine for Medium Size Moulds 70 

VI Roll Over Jolt Machines for Small Size Moulds 92 

VII Jolt Moulding Machines in Brass and Aluminum Foundries 106 

VIII Plain Jolt Moulding Machines 114 

IX Air Operated Squeezer Machines 132 

X Jolt Stripper Moulding Machines 148 

XI Pattern Equipment 161 

XII Flask Equipment 188 

XIII Machine Moulded Cores 203 

XIV Foundations for Jolt Ramming Moulding Machines 209 

Index 222 




A Study in Contrasts 
The man guides the tool. Here the man furnishes the power 

to push the tool. 




Machine Power vs. Human Muscular Power 

The mechanic of today has an easier and better job than the 

laborer of yesterj'ear. 




Hard Work! Tiring and Slow! 



The machine does it quickly 
and accurately. 




The Old Method — Five minutes 
to draw the pattern and one 
hour to repair the damage done. 



The New Method — Five seconds 
after the lever is thrown over — 
ready to set cores. 




5TTOM PLATE 



Rf\M \JPRUNN£RCOFE 



Fig. 1. Plan and Sections of a Well Designed Mould, Explaining the 
Terms Used in the Following Chapters. 



CHAPTER I 

General Moulding Principles 

The foundry industry is rapidly changing from a basis of 
performing labor by hand power to a basis of performing labor 
by mach.ine power. This is evident in all phases of foundry 
work. Arriving material is unloaded mechanically, the sand is 
prepared and carried to the moulding stations by a mechanical 
process moulds are produced by the use of air or other power, 
the casting is handled mechanically from place to place in the 
cleaning room where the work is done by sand blasts, pneu- 
matic chippers and power operated abrasive wheels. To cover 
all the labor-saving devices mentioned would require a much 
larger volume than the present one, which is restricted to mould- 
ing machines and their equipment. The use of moulding 
machines with the resulting high production demands the use 
of other labor-saving facilities in order that the other depart- 
ments of the foundry may keep pace with the moulding 
machines. 

The pattern equipment, flasks, etc., are important items 
that have seldom been given the proper amount of considera- 
tion. Experience has thoroughly demonstrated that in order 
to secure the best results, proper attention must be given to 
e(|ui])])ir,p the machine with patterns, flasks and bottom boards. 
In e(|'iii<ping the machine with patterns, exceptional care 
should be exercised to secure the pattern firmly to the pattern- 
plate, and patterns having a large flat surface should be thor- 
oughly end strongly supported from the bottom in order to 
remove the possibility of a springing action taking place in the 
pattern when the mould is being rammed. If the pattern is 
not properly supported, and a springing action takes place, the 
mould produced will be full of cracks, and if it is the cope 
half of the mould, it will drop out when the flask is being 
handled. 

The flasks also should be examined to see that they are 
rigid and of sufficient strength to prevent a springing action. 




fi./9C£P o/v r//£ r/9gi£ of r//s />r/fcff//v£ 




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ofT as//vs /* r/iLse sarra/^ aav/rc 



TM£ C^lC£ ^/f^s a££Af Clt>S£^. rft£ /YM'/.e' CC/IMr'£j; 



Fiji. 2. Method of Makinji a Mould on the Plain Jolt Machine. 



General Moulding Principles 



The best results have been produced by the use of flasks that 
are cast in one piece. This is especially important when design- 
ing the cope half of the flask, and yet in some instances it is 
difficult to cast integral the flask and the proper bars for sup- 
porting the sand. If it is found necessary to make use of a 
separate bar, it should be secured to the flask by means of 
rivets, or tightly fitted bolts, as a loose bar may prevent the 
making of a satisfactorily rammed mould. 

The above description of the equipment necessary in jolt 
ramming applies to all machines which make use of the jolt- 
ranmiing principle. The rapid change in the foundry industry, 
from a basis of performing labor by hand power to a basis 
of performing labor by machine power, has given rise to some 
popular misconceptions. One of these misconceptions is that a 
moulding machine is a mysterious piece of mechanism which in 
some manner turns out finished moulds at one end of it. The 
exact reverse of this belief is the case, however. A moulding 
machine performs some of the operations that are performed 
by hand moulding, merely taking the hardest part of the labor 
out of the job and eliminating practically all of the guess work 
and chance which go with hand labor. The pages immediately 
following are taken up in illustrating graphically the operations 
of the various types of machines that are used for producing 
moulds. 



Plain Jolt Machine 

On page 2 is illustrated the methitd of producing a mould 
on the Plain Jolt Machine. The six views show the successive 
steps in the production of the mould, steps which will be readily 
recognized by one who has made moulds on any type of 
machine, or on the floor. The operations and the sequence 
of operations are exactly the same as those employed by a 
moulder in making a mould on the floor, with the single excep- 
tion that the machine jolt rams the sand in the flask, an opera- 
tion which the moulder would have done by hand. The machine 
merely does a part of the hard work for the moulder. 



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s^rnrnrni \l 


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V2 


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/3 Pit3r£/f£-ff TV r»£- /fou. cf£» r/)0Le 




THf FLASH /S PL/)C£P l9/fOI/A/t^ TMe PfiTTSfT/^, 





rH£/^jUiP M«j SS£A/ girrr£ff ^/?f r^s fforra/^ 
3ai9Pi? cc/^^rP£ff w /vs/r/oM /W^ r/v£ ^ptcM/zvf 

/i ffOLL//V6 ai'£ff r//£ /IffULff 



m£ /fai/ip /J w/y ffau.£P <7i'£/r ,«*i7 nf let^uMS 
c/i/f /rvA/ wro POi/T/ofj r,^P£C£/y£ ?'»£ moulp 





THF L£)'£UAie P//VJ /iMf £/>C» 0££/V i;£PL£CT£i' 
TH£ /tMOI//^r A/£C£SS/>Pr TO L£y£L r/^£ novLC 
/^/</l7 /ILL r//£ P/nS i.OC^£P Sy ^/V£ L£t'£P 



TH£ P/>rr£PA/ IS B£W6 PP/lirM IS/li'/A/S m£ 

PmiSH£p Mfi/LP aAi r^e i.ef£L/A/6 c/>p. 



Fig. 3. Method of Making a Mould on the Roll Over Jolt Machine. 



General Moulding Principles 



Roll Over Machines 
The next set of illustrations on page 4 shows the Roll 
Over Jolt type of machine producing a mould. The essential 
operations of making the mould remain unchanged and, as on 
the Plain Jolt Machine, the machine jolt rams the sand and 
then, after clamping the mould, instead of the moulder rolling 
it over by his own muscular effort or by the aid of the crane, 
he rolls it over by means of air power applied to the Roll Over 
Machine, and after unclamping it, he draws the pattern by air 
power on the machine rather than by muscular effort and skill 
or by the slow and awkward method of using the crane. It is 
easy to see that such a machine performs the hardest part of 
the moulder's work, and substitutes for muscular effort the 
openinp- and closing of levers and valves. I'age 6 illustrates 
another general type of machine which accomplishes the same 
results a'= the machine illustrated on page 4. The mould is 
jolt rammed, rolled over by an air cylinder, and the pattern 
drawn by air power as in the previous case. The type of 
mechanism employed is essentially different, but the operations 
performed are identical. 

Jolt Stripper Machine 

Pages 8 and 10 illustrate respectively the operation of the 
stripper and of the jolt stripper types of machines employed 
chiefly in making copes. Page 8 illustrates the Jolt Stripper 
machine which jolt rams the mould and then strips it upward 
from the pattern, while page 10 illustrates the Jolt Squeeze 
Stripper machine which jolt rams the mould, squeezes it and 
then strips it upward from the pattern. The essential differ- 
ence in the two machines is that the squeezing operation added 
to the others, eliminates hand butting which is necessary when 
a mould is only jolt rammed. This is done to avoid the addi- 
tional labor and to promote uniformity. Chapter X treats this 
subject in more detail. 

The illustrations previously referred to will easily demon- 
strate to one not familiar with moulding machines, that the 
method of producing moulds by machine power is not a radical 




Q^^^p 




T»£ P/ITT£flN 15 MOUNTED ON THE HOLL OlfER TABLE, THE Fl,/)5M PLACED ON FIUEO 
mTH SUNO AND JVL T RAMMED 




THE MOULO HAS B££N BUTTED I7FF, THE OOTTOM BO/tffP CLAMPEO 0/v, THE Mai/LP 
POLLED OI/EP AND THE LEfELING TABLE fTAISEO UP AGA/N5T THE saTTOM BDAAO 




THE LEVELING TABLE HAS BEEN LOHTPEO THl/S OPAH/Z/VG THE PPTTEPN 



Fig. 4. Method of Making a Mould on the Roll Over Jolt Machine. 



General Moulding Principles 



departure from the old and established methods of producing 
moulds, but that machine moulding is merely the substitution of 
air or other power, in place of human muscles, thus doing away 
with some of the most disagreeable tasks of. foundry work and 
making the foundry a more pleasant, wholesome and profitable 
field in which to work. 

Squeezer Machines 

The moulds referred to thus far arc all larger than the 
class of work known as squeezer work, which on account of 
its small size can be easily handled by one man even when 
the flask is full of sand. Such moulds do not re(|uire machine 
power for handling, but it has been found tliat machine power 
can be advantageously substituted for hand power in the ram- 
ming of the sand. Page 12 shows the sequence of operations 
of the Plain Squeezer Moulding Machine, which is so well 
known to everyone connected with the foundry industry, since 
it is the oldest form of power machine. Its sole function is 
to ram the sand by squeezing, and the remainder of the work 
is done by hand. The Jolt Squeezer Moulding Machine, the 
operation of which is illustrated on page 14. adds the jolt fea- 
ture to the well known Plain Squeezer, and eliminates the hand 
tucking which is necessary on practically all drags. It enables 
the operator to turn out either more moulds with the same 
efifort or the same number of moulds with less effort. Chapter 
IX goes into this subject in greater detail, taking up the par- 
ticular advantages gained, and the kinds of patterns on which 
the Jolt Squeezer Machine is of great advantage as compared 
to the Plain Squeezer IMachine. 

There are types of machines other than those mentioned 
above, but the examples discussed are typical ones which embody 
prac'tically all of the principles that are used in the foundry 
today. The other types of machines which have not been 
mentioned, are dififerent combinations of the same fundamental 
principles, and the adoption of this or that type of machine is 
frequently a personal matter with the foundryman. 




r»e p/>rr£f>rt is inow/y /^ountei; on the patt£/m 

PL/iT£ mc'J(Mffix'W£p gr/iM /Kcvmrtw f/rr//vs 

ST/fipp/na PL /ire 




mf Fi./ISff M3 B££n PL/!C£i' /fffOe'^/P TM£ 




TH£ /^/>CM/f/£ ///!^ J'OLT ff/lftflf£P TH£ S/I/Vff. 

oamive tmh OP£/f/rr/iw 7»£ s/u^Ai sfvfepp er 

H/l/io 



TH£ ffOVLP H/IS BEEN BUTTED OFF flNP THE 
POU»ll\IS BASIN FINISMEP 






THE MOi/Lff H/)S ffeS/V STfflPP£P F/fOM THe 

F'/)rr£ffN Br the upward MoygMENT of 

THE STPlPPlnS PL/>T£ /)NP ISNOtfCO/^PLETEO. 



7ME ftPCiff /*U BEEN LIFTEP FROM 7f/£ STPIPPINS 
PL/}T£ /fNO li SHOWN FfEHCr TO C10S£. 



Fig. 5. Method of Making a Mould on the Jolt Stripper Machine. 



General Moulding Principles 



The foregoing explanatory matter is not intended to be a 
complete guide to the use of moulding machines ; it is elemen- 
tary in nature and is inserted for the purpose of giving the 
reader a broad view of the subject before taking up in detail 
the operation of each machine. This will be done in later 
chapters describing the machines. 

Processes of Moulding 

The explanations given in this chapter are not intended 
to be complete and, in the absence of direct reference to other 
chapters, the reader is referred to the table of contents for 
more information on the matters which will be covered briefly 
in the remainder of this chapter. 

In order to allow the mind of the reader to dwell upon 
the important points covered in the succeeding chapters, it is 
necessary that a comprehensive view of machine moulding be 
firmly established in mind so that the details will be clear 
and no additional attention need be paid to them in the subse- 
quent chapters. Accordingly some of the relatively minor 
matters of machine moulding will be gone into in this chapter. 

Pattern Mounting 

Another of the common misconceptions in regard to the 
use of foundry moulding machines is the idea that the mount- 
ing of the pattern is an operation of great cost, requiring a 
high degree of skill. While it is true that good workman- 
ship is required in mounting patterns for machines, the state- 
ment holds true even though the patterns are to be used 
by hand, that good workmanship is always necessary for the 
production of good results, and certainly, pattern mounting 
is no exception to this rule. Any good pattern-maker may 
easily study out the steps which are necessary in the mounting 
of patterns for machine moulding, and with a little experience, 
will find it very simple and not more difficult than the con- 
sideration given to the making of the same pattern for hand 




/=L/)T£ /J ^v/ffiovNPea BY AN /icct//r/>r£/.r 
FirriNs srmPfMe pl/ite 




rMSn./9S/f IS PL/ICEP /iffOt/NO me P/)TT£/fN, 

p/LLee mrM ^/i/yc -^/v^ •jolt pi/immsip. 





TM.5 sice y/s)v if/aivs how T//£joi/££z//v& 
ff£/iff Moyss Poffw/)/fp sTmniNe OPPTHE 

.SUffPLUS S/)W/U /T/iOfES. 



T»£SOl/££Z£R H£AP IS /ILL TM£ If/iy POffW/llfP 
/>NP nE MOULP H/)S JI/ST BEEN SOVEEZEff. 






T»E /</0(/iiP H/)S BEEN STmPPEO PPO/t THE 

P/^TTEnN Br THE UPHf/IPP MOfEfiENTOPTHE 

iTRlPPINt PL/tTE /thP IS mOMfConPLCrEP. 



THE COPE /J /IMPE /N /) J/M/Li9R M/iNNER 
EXCEPT POR THE SPTE THIS yiEtV .SHOWS 
THE PPiQS l/SEP WITHOl/r/) BOTTOfi BO/lffP 
WITH THE COPE SET SNP THE COPE /IBOyE 
ffEHPr TO CLOSE THE fiOULO. 



Fig. 6. Method of Making a Mould on the Jolt Squeeze 
Stripper Machine. 



General Moulding Principles 11 



moulding. Essentially the difference between patterns made for 
floor moulding and those made for machine moulding are as 
follows : 

In patterns made for floor moulding it is assumed that 
the moulder is a highly skilled workman who is able to over- 
come many moulding difficulties, and consequently it is assumed 
that since he is working with moulding sand, which is more 
readily fashioned than wood, he should be called upon to do 
the extra work necessary at the expense of the patternmaker 
who makes the pattern in the simplest manner possible, 
simplest, that is, from the standpoint of making the pattern. 
However, when mounting the patterns on machines, some 
method of securing the pattern is necessary, and it is common 
to build the pattern onto the board which forms the parting 
of the mould. Rather than force the moulder to cut an irreg- 
ular parting, it is now considered good practice for the pat- 
terninaker to cut this irregular parting once and for all, and 
to relieve the moulder of this work. An important economy 
in the total amount of time spent in the producing of the 
casting is thus obtained when any quantity of castings is to be 
made, and, uniformity of method is assured, whereas different 
moulders might . adopt diiTerent methods and every casting 
would vary, to the subsequent disadvantage of the machine 
shop. Mounting patterns on a moulding machine is not a 
difficult matter, and does facilitate the making of the pattern 
in such a way that the total amount of labor spent in the 
pattern shop and foundry compares favorably with the total 
amount spent in producing the casting by the old hand method. 

Chapter XI on pattern equipment will present many of 
the details of pattern mounting but it should be said in this 
connection, that any pattern made for machine moulding 
can be rammed by hand on the floor, rolled over by hand or 
crane, and the pattern drawn by hand, thus demonstrating 
the fact that machine moulding is essentially the same in 
principle as hand moulding. 



^^^^M 




THe COP£ H/ILP OF TH£ SVAPFLfiiH r»£ 
P/ITr£f^N PL/^T£ /l/VO rue OR/16 HfILP Of 
THE S/V/)P FLAiK /iR£ PLACCO INi/ePTEOON 

TH£ r/igL£ OK rHC m/ichi/ve in tme o/iae/t mrio 



Q QOt^ ^ 




TV£ ORA6 IS FllL£0 HffTM S/tfll0 »/»NO TVCfEP 

O/V THE SIPEi ^NOINR»y POCHETS STPCK/f OFf 
/IMO THE BOTTOM gO/)RO PLACED ON 




THE MOI/LO HAS Been ROLLED <?**>? THE COPE 
PILLEO mTH JA»0 Tt/Cft£0 STRVCM ffrF /INO 

THE ^ai/e£Z£ aoHRO plrc£0 oh 




TH£ MOC/LO IS IVOW SOI/EEZ£P BOTH HAL^ei 
/IT THe S/lfllE TIME 





RSSI-iTEO BT THf i'/BRATOP THE COPE IS OlMfW 
HP PRO/* THE PATTERN PLATE Pl/T A5/0£ A/VO 
THE PRTTERN PLATE ORAtV/V UP PROn THE 
ffRAS 



THE COPE IS CLOSE ff O/V THE- ORA6 THE S/^p 

PLAiH RE/IOfEO /IDIO THE P/IV/SHEO /tOt/LO 

'5 ReAffy TO B£ PI RCEO ON THE PL OOP 



Fift. 7. Method of Makinji a Mould on the Plain Squeezer Machine. 



General Moulding Principles 



13 



Jolt Ramming Operation 
The jolt ramming operation is combined with various 
other machine operations and is embodied in many types of 
machines. It is, therefore, one of fundamental importance. 
The importance of this operation and the theory of it will 
be covered fully in Chapter II, and the machines performing 
it, in subsequent chapters. At this point it might be well, how- 
ever, to point out some features in regard to this operation. 

Use of Upset 

The sand, in packing down into the flask at each blow 
of the machine, necessarily drops down into the flask, and it 
is necessary to pile sand as high as it can be held on the flask 
before jolt ramming. On some deep flasks it is not possible 
to pile enough sand, and in such cases an "upset" is placed 
around the flask for the purpose of holding more sand. 
This upset is removed during or after the jolt operation when 
the san-l has jolted down into the flask. An upset is shown 
in use on page 8 at the upper right hand corner of the page. 
When jolting down into the flask, the sand will to some 
extent, follow the outlines of the pattern, as is clearly shown 
l)y th<' top ilhistration on page 16, in which, at the extreme 
right of the flask, the sand has jolted down below the top 
of the flask, while immediately above the pattern, it has been 
supported and is above the flask. 




Fig. 8. The Use of a Gagger. 



Use of G aggers 

In producing the cope or 
upper half of the mould on 
the jolting Machine, either 
the Plain Jolt or the Roll 
Over Jolt, it is frequently 
necessary to make use of gag- 
gers. as in floor moulding 
practice. The gaggers are 
used in identically the same 
way and no difficulty is ex- 




Tf^ coPc HALF a/=' r//e samp f-lash, rue 

^nrreff/l/ PLATE /iA/O THE OP AS HALF OF 
THE ■SAI/IP FLASK F)/?E PLACEP IHfEPTEPON 
THE TABLE OF THE /^ACH/HE If THE CAOEA NAnfO 




THE DPAS 15 FILLEC tT/TH SAW, JOLT PAFtFtEff, 
STPVCM OFF A/VP THE BOTTO/i BOAPO PLACEP OH 





TME /^at/LO HAS BEEni POL LEO Ot^EP, THE 
COPE FILLEO W/T» SAHO, rVCH£O,STPVCH0FF 
PnO THE SO(/££Z£ BOPPO PLPCEO O/V. 



THE fiOULD IS /VOIV SOl/EEZEC BOTH HALITES 
/)T THE SAME TIME 





PSSISTEO 3r THE i//BPATOP THE COPE li OPAtf/V 
e/P FPO/^ THE PA 7 TERH PL P TE Pt/T Pi/OE P/HO 
THE PPT TEP/V PLATE DPPITH CP FPOM THE 
OPP6 



THE COPE IS CL03EP O/V THE DPPS, THE 
5/VPP PL/fS/1 PEAfOi'ElP P/VO THEF/ly/SHEO 
/fOt/LO /S FIEPOr TO BE PLPCEO OH THE 
FLOOP 



Fig. 9. Method of Making a Mould on the Jolt Squeezer Machine. 



General Moulding Principles 15 

periencfd in jolt ramming them by machine power. Figure 8 
shows the usual method of setting gaggers against a bar wath 
the foot of the "L" shaped gagger projecting into the pocket 
of sand, which is to be carried, and which needs this addi- 
tional support. It might be well to call attention at this time 
to the fact that gaggers should be dipped in a clay wash before 
being placed in the mould in order to make their use more 
effective. 

Spreading the Sand 
Although there is enough sand in the flask it is necessary, 
before butt ramming, that this sand be distributed evenly 
over the flask, and this operation naturally requires a small 
amount of time. In order to eliminate as much of this 
time as possible, it is good practice to spread the sand from 
the center of the flask toward the edges, by hand, during 
the jolt ramming operation, so that at the completion of the 
jolt ramming the sand is left in a shape such as that shown in 
the bof.om view on page 16 which shows the sand so distrib- 
uted that it can immediately be butted off. 

Butting Off 
"Butting off" the mould has been mentioned several 
times above. By this term is meant the hand ramming which 
is necessary to stipplement the jolt ramming of the machine. 
When a machine jolt rams the sand, a sufficient density of 
sand is produced on the pattern and pattern plate, but near 
the top of the flask the sand is not rammed so tightly and is, 
in fact, so loose that it requires additional ramming. This is 
done by hand and can be done very rapidly since no special 
skill is required, as the part of the motild requiring skilled 
ramming has already been rammed by jolting, and it is neces- 
sary only to pack the sand tightly at the top in order to 
support the portion of the sand adjacent to the pattern and 
pattern plate when the mould is being rolled over, while it is 
resting on the floor, and during the pouring operation. "But- 
ting off" is a hand performed operation in the making of the 
mould, and it is onlv natural that one mould will be butted 







WPEff THE Pff£5SUff£ /lAlP MTl/fMLLy /)S5(/M£S /9 3H/)P£ 

sucA/ /IS TM/ir SMtH//^ /)0oy£. TM/5 /s aaJ£cr/o/i^/)aiswrH/>T 



\ /'=K'J/7V«W <?/^ T/i£ S/lAi:? 
^ X B££afl£ JOL T fr/>/^f1/fll6 




rf//3 /VOt/Le' M/li £f£OC///!£ L£SS r/M£ rOff BUTT/ZVC 0£f r///>/V 

THe MouLO sMoiv/v /looye. rws ^/ivof>/>BL£ c/ffCi//^sr/!A/c£ 
/s iOffoei/csp ar s/'/rs/iff/A/s TNe s/^/^e f^/roM r//£ csAfre/^ 
TO r/i£ £ifs£s Of rH£ f'L/fSfi Di/niNS rue JM.T nA/in/MS ofV/f/inoN. 



Fig. 10. The Sand Should be Spread During the Jolting Operation. 



General Moulding Principles 



off to one degree of hardness and the next mould to a differ- 
ent degree. This difference does not appreciably affect the 
size of the casting when it is used for ordinary work, but 
is objectionable when extremely accurate castings are required, 
such as those used in the automobile industry. This differ- 
ence, slight as it is, causes trouble in jigs which are made 
for accurate work, and makes it advisable to employ a machine 
operation, that of squeezing, for butting off the mould. This 
will be discussed more fully in the chapter which deals with 
Jolt Stripper and Jolt Squeeze Stripper Moulding Machines. 

Striking OiT 
After the sand has been butted off, it is necessary to clamp 
in position a bottom board, the same as in hand moulding. 
This bottom board must support the sand evenly over the 
entire surface of the mould, both during the roll over opera- 
tion and subsequently on the floor and during the pouring 
operation. This bottom board must be bedded onto the flask 
correctly, and this is done in the following manner : The top 
of the mould is "struck off" with a straight edge, either wood 
or steel, so that the sand over the entire mould is exactly 
level with the top surface of the flask ; a hand full or two 
of loose sand is then scattered thinly over the surface of the 
flask and the bottom board is placed on and worked back 
and forth by hand until it makes for itself a solid bearing 
over the entire mould. This extra sand is not necessary 
because the flask is out of alignment, but because the bottom 
board is always a little warped or burned in places, due to 
its having been subjected to extreme heat and to water. The 
strike off operation consists simply of scraping off the excess 
portion of the sand, and is performed by the use of a wide 
or a narrow bar, depending upon the size of the flask being 
struck off. Figure 12 illustrates the use of a wide and a 
narrow strike-off bar. In this case, since the flask is of 
medium size, the wide strike-off bar has an advantage in that 
the mould can be struck off in one stroke. This is not 
true of the larger size of flasks, where a wide bar would hold 
so much sand that it would be difficult for the moulder to 



(jciwral Moulding F'linciples 



19 



draw the bar. In such a case a narrow bar has the advan- 
tage of cutting through the sand, loosening it all thoroughly 
on the first stroke, and yet removing at every stroke as much 
as it is practicable for the moulder to handle. 




/^/V/W-w*- sr/f//r£ o/^F PEffAf/rs the s/i/ve? ro 
sfiLL <?>'£/> THi/s A/ecenimr/MQ /isecoNo 



Fig. 12. The Use of Wide and Narrow Strike Off Bars. 

The clamping of the pattern, flask and bottom board 
together, needs no comment here and the rolling over is also a 
very simple operation and needs no further comment. 

Pattern Drawing Operation 
Removing the pattern from the rammed sand is performed 
in essentially the same manner on the machine as on the floor, 
namely, the pattern is lifted vertically, or as nearly vertically 





5.1 














General Moulding Frinciplei 



21 



as possible, from the sand. The details, however, vary greatly 
in the two cases. In floor moulding the pattern is rapped 
i)ack and forth and from right to left by using a maul or 
hammer on the rapping pin. which is inserted in a plate built 
into the pattern for this particular purpose. This rapping 
damages both the pattern and the mould and also makes 
the mould over-size. The pattern is then drawn by the aid 
of lifting hooks which are attached to plates built into the 
patterns and. accompanied by additional rapping, the moulder 
lifts the pattern as nearly vertically as possible. Contrasted 
to this method, the machine operator opens a valve, which 
places the vibrator in operation, and then opens another valve, 
which places in operation an air cylinder, which either draws 
the patiern upward from the mould or the mould downward 
from the pattern. 

The Vibrator 

The vibrator, which is a device similar to a pneumatic 
hannner, is shown diagrammatically in h'igure 14. It is attached 
either to the ])attern or to the table of the machine to which 





^/NT/IHE 






•isijz. '/. '/f y(^P////M////<'////y^W/ 


V/^/r 




^ Kj|.|||||||||iJ|| 


ii 


1^ 


^ 


r :z ],.. 


^i^r^'Z-i YV/A///////////////////////y 


y/}/-'. 









Fig. 14. Diagram of an Air Operated Vibrator. 

the pattern is rigidly fastened. In either case the reciprocat- 
ing action of the vibrator produces a series of shocks which 
are transmitted to the pattern. These shocks are of such 



General Mould ing Principles 23 

small intensity that no measureable enlargement of the mould 
takes place, and yet the friction of rest existing between the 
pattern and sand is overcome, as is also the friction of rest 
existing between the various parts of the machine which 
accomplish the pattern drawing. The action of the vibrator 
accomplishes perfectly the result for which it is designed, 
and has the advantage of not damaging the pattern. 

0\crhanging Projections 
The drawing of the pattern assumes a pattern which, in 
the trade term, "has draft." This means that the pattern is 
of such a shape that it can be drawn vertically up ou* of the 
mould, leaving behind it the sand of the same shape as the 
pattern, without tearing or breaking the edges of the sand. 
The design of many castings is such that the pattern has 
overhanging projections which cannot be drawn from the sand 
in the usual manner, and special methods nuist be employed 
in such cases. Two means are generally employed — first, the 
overhanging projections of the pattern may be made loose, 
so that when the main pattern is drawn this auxiliary portion 
of it remains embedded in the sand of the mould, and is 
drawn separately in another direction into the cavity left by 
the withdrawal of the main pattern. This method is illus- 
trated on page 18 which shows the sequence of operations in 
ramming up a mould from a pattern containing a loose piece, 
and the subsequent removal of the loose piece, leaving in the 
mould a cavity of the desired shape. 

Cores 

A second method of ]:)roducing such a casting is by the use 
of a core, which is a separate block of sand, that has been 
baked veith a binding material and is hard so that it retain.s 
its shape and can be placed in the cavity of the mould after 
the pattern has been withdrawn. Extra allowance must ha 
made on the pattern for the core which will be introduced 
into the mould later. This portion of the pattern is known as 
the coreprint because it leaves an impression which wull be 



General Moulding Principles 



tilled bv the core. Page 20 shows the method employed in 
making a casting by means of a core which is set into the 
mould after the pattent has been withdrawn. It can readily 
be seen that this core must have sufficient bearing surface upon 
which to rest, and must be anchored firmly in place so that it 
will not float loose when the mould is poured. In this case 
the projections at the top and the bottom of the core are used 
for locating and for holding it tirmly while the mould is being 
poured. Sometimes cores are the only method of solving prob- 
lems similar to the one discussed above, but there are many 
uses for cores other than as a substitute for a loose piece on 
the pattern. Cores are frequently used where a rather thin 
body of sand would be washed away by the flow of metal 
into the mould ; to produce holes in the side walls of castings ; 
to support heavy cores which must be set later ; to receive the 
impact of metal which falls vertically thru a portion of the 
mould ; and for other purposes. 

Ram Up Cores 

The term "ram-up core" is frequently heard in the 
foundry and occasionally a mistaken view is held that a ram 
up core cannot be rammed on a jolt machine. Page 22 illus- 
trates clearly one of the many uses of the ram up cora. It 
derives its name from the fact that it is placed on the pat- 
tern and remains there while the sand is rammed, whether 
this is done by hand ramming or machine ramming. When 
the pattern is drawn the core is left firmly embedded in tlie 
sand of the mould for any one of a number of purposes. 
On page 22 a ram up core is shown in use for the purpose 
of supporting the concentrated weight of a heavy core, which 
otherwise would have crushed the green sand at this point. 

Inserted Cores 

Another form of core of similar purpose is the "inserted 
core" which is of such shape that it cannot readily be rammed 
up on the pattern due to overhanging projections, which would 
cause trouble bv breaking of^", and also would require hand 








9^ 







£| 
^^ 

St- 

Sl< 
"-I 






V .. ^, /a I 










General Moulding Principles 



27 



tucking beneath them. The method of inserting such a core 
is shov.-n on page 24. wliich shows clearly that the mould 
is jolt rammed, a hole is dug down to the loose piece, which 
is then removed and the inserted core set in place, the ramming 
being completed by hand. This kind of a core is correctly 
called an "inserted core," but is of the same general class 
as a ram up core. 

Covering Cores 
The term "covering core" is frequently used in the 
foundry and page 26 illustrates the method of its use in a 
casting where the covering core also serves as the cope half 
of the mould. The illustrations on that page are self-explana- 
tory and need no further comment here. 

Cjating 
Reference has been made to the pouring of the mould 
and to the flow of metal into the mould. The passageways 
provided for the metal to enter the mould are known as the 
"gate," and the making of them is known as the operation 
of gating. The term, "gate," 
includes the pouring basin 
into which the metal is 
poured directly from the la- 
dle, and all parts of the pas- 
sageway leading from the 
pouring gate to the cavity 
forming the casting. In 
Squeezer work it is cus- 
tomary to refer to the ver- 
tical portion of the gate as 
the "sprue," and to the hori- 
zontal portion of the gate as 
the "rimner." Other spe- F'g- 18. Diagram of Swirl Gate. 
cial names are applied to gating, indicating the method em- 
ployed to prevent dirt and slag in the iron from entering 
the mould ; thus the names "skimmer gate," "strainer gate" 
and "swirl gate" are practically self-explanatory. The typical 
mould illustrated in Fig. 1 contains a strainer gate which 





28 Foundry Moulding Machines and Paitern Equipment 



consists essentially of a strainer core placed in the g"atin_ij^ 
system at some convenient point, a strainer being a core per- 
forated with a nnmber of small holes which permit the passage 
of the iron bnt keep out the sla;,^ and dirt. I'he swirl gate 
is illustrated in Figure 18. In this gale the iron is led into 
a circular basin which it enters at an angle, causing the iron 
to rotate rapidly in the basin. Any slag or dirt floating on 
it will collect in the center, and the clean iron is drawn 
from the outside edge. The basin into which the iron is 
poured from the ladle is so shaped that, to some extent, 
it insures the entrance of clean iron into the mould. /\.n 
aluminum pattern is used to form pouring basins of uniformly 
correct shape. The views on page 8 illustrate the method 
of usiri'^ it and the typical mould in Figiire 1 illustrates the 
shape of the basin and its position in the finished mould. In 
using it. the iron is poured into the larger of the two depres- 
sions until it flows over into the smaller one and down the 
gate. The basin is kept full of iron by rapid pouring, and the 
slag accumulates on the top. allowing clean metal to enter the 
gate. When first starting to pour, a small amount of slag 
is likely to be carried down the gate before the basin is fuil 
and tliis slag may get into the casting and cause trouble. 
In order to prevent this, some foundries place a small piece 
of thin sheet metal over the gate entrance. This holds back 
the metal until the slag has had time to rise, and insures only 
clean metal entering the uKutld. The sheet metal then melts, 
admitting the iron. 

The point at which the iron is introduced into the mould. 
and the rate of flow of the iron as determined bv the size 
of the gate, the height of the pouring basin above the point of 
entrance, and the fluidity of the iron are matters of great im- 
portance in securing a good casting. Oifficultv has been ex])eri- 
enced in a number of cases in wliich the castings were bad 
until some change was made in the gating system, after which 
good castings were obtained. 

Although the subject of gating is one of great importance. 
it is a subject upon which very little can be said from a 



General Moulding Principles 29 



llieoretical staii(l])()iin. and the subject remains the exclusive 
Tield of the skilled and exj)erienced moulder, when machine 
moulding as well as when hand moulding. This point should 
be noted, however. The tyi)e of pattern emj)loyed on mould- 
ing machines, being mounted on a permanent plate, readily 
adapts itself to the use of a gate pattern l)uilt onto the l)oard 
in such a way as to be a permanent part of the pattern ecjuip- 
nient. thus insuring uniformity of gating, and after experiment- 
ing to secure the best gate, it then becomes an automatic matter 
tliat each subsequent mould has the best gate, whereas the 
most skillful of moulders, in cutting each gate individually, will 
vary slightly from time to time. The result of past experi- 
ence in gating seems to be a sort of intangible knowledge which 
takes the form of judgment, which has not been expressed 
by a definite set of rules. 

Moulding Sand 

The proper moulding sand is an absolute essential in pro- 
ducing moulds either on the floor or on the moulding machine. 
The selection of moulding sands is rapidly assuming the aspect 
of a definite science of sand grading, and some important 
research work along this line has recently been done. The 
major portion of this information has been published in the 
Transactions of the American Foundrymen's Association, vol- 
ume XXI, page 19, and the tests for grading moulding sand 
are briefly recapitulated here as follows : 

1. A general microscopic test which provides general 
information in regard to the chemical composition of the sand,, 
size of the grains, their shape and the amount of bond. This 
test eliminates those sands which are readiK- recognized as 
unsuited to motilding purposes. 

2. Rational chemical analysis of the sand gives directly the 
quartz, clay and feldspar contained in the sand. The per- 
centages of these various elements determine the fusibility of 
the sand, and consequently determine whether or not it can 
be subjected to the heat of the molten iron. 



30 Foundry Moulding Macliinrs and Pattern Equipment 

3. The fiiK'iH'ss of the sand is determined by the per- 
centage ot the total passing thru a succession of screens of 
20, 40, 60. 80 and 100 meshes to the inch, respectively. A 
coarse sand ma}- be used for heavy work while a fine sand 
is required for finer work. In addition to this, there also exists 
the factor that a sand composed about one-half of relatively 
large grains and the other iialf of relatively small grains will 
not vent well, because the small grains will so completely fill 
the spaces between the large grains that the gases will not 
have sufificient room for escape. 

4. The transverse strength is tested on a specimen of the 
sand prepared and tested under standard conditions. This 
takes the shape of a bar 1" square. Ay^" long, supported A" 
apart and broken h\ the application of a weight at the center. 
This test is made with from 5% to 7V2% moisture and a 
second test with 10% moisture. 

5. The crushing strength is measured on a standard V* 
square block of sand 2I/2" high. 

6. The permeability to air is measured on a 2" square 
block 1" thick prepared under standard conditions with a 
given quantity of air forced thru the sand. This test checks 
to some extent the information obtained in test No. 3. 

7. The strength of the clay bond present in the sand 
is measured by the percentage of dye absorbed per unit of 
clay in the sand. It is readily seen that this is not a test of 
the amount of clay present, but of the strength of the clay 
which is present. 

These seven fundamental tests for moulding sand form 
the basis of proper sand selection and their importance should 
not be overlooked. In the absence of laboratory facilities, a good 
magnifying glass will furnish much valuable information in 
regard to the properties of the sand, provided the significance 
of what is seen is fully understood. Many sand troubles 
may be avoided by the use of a good magnifying glass. 



CHAPTER II 

Theory of Jolt Ramming 

Recent foundry development has produced no one opera- 
tion which is more fundamental than the jolt ramming opera- 
tion. It accomplishes the ramming of the mould in a more 
satisfactory manner than the squeezer machine and is applica- 
ble to all sizes of moulds from the smallest to the largest. The 
theory explaining the jolting action of a machine in ramming 
the mould is of such fundamental importance that a chapter 
is here devoted to it. The importance of this operation is 
emphasized by the fact that practically all machines, having 
more than one operation, incorporate the jolt operation for 
ramming the sand in the mould. Common examples are the 
jolt Roll Over Pattern Draw Machine and the Jolt Squeeze 
Stripper Machine. 

Every foundryman is familiar with the skill required in 
the production of a hand rammed mould ; with the exactness 
of ramming which nuist be obtained over the pattern of vary- 
ing shaj^c and at varying depths in the flask. .\ perfect cast- 
ing requires perfect ramming — a thing that is very hard to 
attain in practice. The least defect in the ramming causes 
swells, scabs, blow-holes, or run-outs. When such a task is 
undertaken by hand-ramming, trouble is experienced in secur- 
ing a mould with a surface of uniform hardness and without 
the adjacent hard and soft spots, which, when the metal is 
poured, cause the gases to flow along the surface of the mould 
to the soft spots instead of entering the surface of the sand 
without flowing. 

It is obvious that the moulder cannot, without exceptional 
skill, produce with his small tamp a surface of even strength 
and texture without setting up initial strains in the body of 
the sand. The pouring of the hot metal against the rammed 
sand weakens the binding elements and releases the strains 
caused bv uneven ramming, allowing; the sand to flow in the 



Foundry Aloulding Machines and Pattern Equipment 



path of least resistance until it becomes of uniform hardness, 
sufficient to withstand the pressure of the metal. This move- 
ment of the sand is one of the causes of the rough, uneven 
surfaces that are usually seen on the castings produced by 
hand-rammed moulds. In contrast with the above described 
hand method, in the mould that is produced by jolt ramming 
on a machine, the iron will lie properly and the gases, with- 
out flowing, will immediately enter the sand, jolt ramming is 
accomplished by lifting the table, pattern, flask and sand a 
short distance and then allowing them to drop and contact 
with an anvil which stops and reverses the table, pattern, an(3 
flask but allows the sand to continue in its descending coin"se, 
producing a pressure in the sand, especially in that sand lying 
nearest the pattern and pattern plate. By repeated machine 
blows the sand is caused to flow to the bottom of the mould 
and to pack into the flask corners and around the pattern in 
a uniform manner, the jolting action o^ the machine causing 
the grains of sand to flow in the direction of least resistance, 
and, therefore, the mould is packed in an even and uniform 
manner and without setting up unequal strains between the 
various particles of sand or between the several parts of the 
mould. 

The development of the jolt ramming method of moulding 
has produced a machine that will jolt ram a mould complete 
in from 5 to 30 seconds of time, operating with a stroke of 
V to 2" in length, and at a rate of 150 to 250 strokes per 
minute. One should not lose sight of the fact that jolt ram- 
ming the mould properly, is only the first operation performed 
on the mould, and that it is easy for the moulder to introduce 
the variable human element in the latter stages of the work; for 
instance, a mould which has been jolt rammed may be im- 
properly butted off; the pattern may be hand drawn so crudelv 
as to dan^age the surface of the mould, requiring a great 
amount of slicking and patching. These variations introduced 
in the latter phases of making the mould will eliminate some 
of the advantages of jolt ramming. This constitutes a verv 
strong reason in favor of the machine which not onlv jolt rams 



Theory oj J oil Ramming 33 



the mould but which performs the subsequent operations of 
butting off, rolhng over and drawing the pattern, with an 
accuracy and uniformity equal to that of the jolt ramming. 

Since the saving in time effected by means of jolt ramming 
is usually not more than 50 per cent of the whole, it is advisa- 
l)Ie that more time be saved by using a machine that not only 
jolts but also rolls the mould over and draws the pattern from 
the sand. These operations are being performed by machine 
power in from 10 to 60 seconds of time, producing a mould 
that has rot been distorted or broken, and leaving the patterns 
undamaged by rapping. 

Ramming Requirements 

The requisites of ideally rammed moulds, then, are as 
follows : 

(a) Uniformly rammed sand. 

(b) Correct density in various parts of the mould. 

(c) Uniformity of various moulds made from the 
same pattern. 

These lequirements necessitate the use of a suitable grade of 
moulding sand, properly prepared. 

Taking these points and considering them separately, we 
find that the jolt ramming of a machine produced an equal 
force over the surface of the pattern and pattern plate and this 
equal force, acting against the equal resistance of the sand, 
produces an equal result over the entire pattern. The ma- 
chine, then, normally produces a mould which is of uniform 
density throughout, whereas a moulder, after nuich training, 
can only approximate this desired condition. 

The second point — correct density — is subject to the same 
influences. The machine can readily be adjusted to give a 
harder or softer blow, which, coupled with the number of 
blows, will ram the mould to any desired density within given 
operating limits. A moulder, on the other hand, attempts to 
match his skill against the machine in producing a proper den- 
sity of sand and invariably comes out a poor second. 



34 



Foundry Moulding Machines and Pattern Equipment 



The third point — unifoniiity of dilTercnt moulds made 
from the same pattern — is of great imjiortance to the user of 
castings. Accurate weighing shows that the castings produced 
near the end of tlie day hy hand labor are heavier, due to soft- 
er ramming on the part of the tired moulder. The difference 
will amount to an appreciable sum in the first cost of the 
castings to the user, and probably even more expense will be 
incurred in the machine shop, for these oversize castings give 
trouble in jigs and on the layout plates. 

It lias been found that to produce a machine that will 
quickly jolt ram a mould in the manner described in the pre- 
ceding paragraphs, there should be no pause in the upward 
action of the stroke, but, on the contrary, the upward action 
of the stroke should start rapidly and at the instant of table 
contact with the anvil, in order to prevent the moving parts 
from coming to rest at the end of the slight rebound stroke 
due to impact only. If this impact rebound is allowed to ex- 
pend itself before the table again starts on its upward stroke 
bv means of the air power, the ])ressure on the sand is then 
released, and instead of being compressed the sand itself re- 
bounds and retards or destroys the packing action. Machines 
that do not make use of this pressure require a longer time 
in which to pack the sand. 





FiS-19. Indicator Tests F*g- 20- 

Indicator cards taken from such a machine are as shown 
in l-'iguies 19 and 20, in which the extreme width of Fig. 19 rep- 



Theory of Jolt Ramming 



3.J 



resents the pressure required to lift the table with equipment, 
and the extreme width of the shaded portion of Figiu-e 20 rep- 
resents the pressure in the cyhnder at llie time of eontact. 
Since the indicator diagram ( I'^ig". 20) shows that the pres- 
sure in the cyhnder at the time of contact is only one-half 
of the amount required to lift the load, it is obvious that the 
moving parts will rebound, and that, without sufficient pres- 




Fig. 21. 




Fig. 22. 

sure in the cylinder, the moving parts will, when the force of 
the rebound is spent, settle back again until sufficient air is 
admitted to the cylinder to obtain the pressure required to 
again lift the load. 

The indicator cards shown in Figures 21 and 22 are taken 
from a machine having a balanced piston type valve, so con- 
structed as to close the exhaust ports, thereby trapping the 
air in the cylinder and also admitting line air to the cylinder be- 
fore the falling load has contacted with the anvil. This pro- 



36 



Foundry Moulding Machines and Pattern Equipment 



duces, iindtT ilie ])iston. a high pressure, j^reater even than 
line pressure. I'his high pressure is present just hefore the 
piston contacts at tlie bottom of the stroke, and prevents the 
moving parts from settling back again after the rebound at 
the beginning of the stroke. Upon contacting, the table re- 
bounds ?nd then proceeds steadily upward under full line pres- 
sure, maintaining the packing force generated in the sand by 





Fig. 23. 

the impact. This force, by remaining upon the sand longer, 
naturally produces more packing efifect on it. 

The width of the shaded portion ol" iMgure 21 represents 
the air pressure required to lift the load; the width of the 
shaded portion of I""igure 22 re])resents llie pressure developed 
by the downward movement of the piston acting upon the air, 
at atmospheric pressure in the cylinder, after the exhaust is 
closed, and also upon the admitted compressed air ; the re- 
sulting pressure is from 10 per cent to 20 per cent higher than 
the pressure ref[uired to lift the load, and takes place at a point 
in the stroke just liefore contact is made, and therefore, 
cushions the blow so that the force of the blow is not trans- 
mitted to the base and fovmdation. the contact being necessarv 
only to cause a (juick antl decisive reversal of the moving 
parts. 

There are no heavy strains set up in the falling parts as 
would otherwise be the case if the whole load were allowed to 
fall with the full force of gravity. The action obtained in the 



Theory of Jolt Ramming 



moving parts is rapid, and at the time of contact with the anvil 
these parts arc resiHently reversed in their (Hrection of travel, 
while the sand, being loose and semi-litiuid, continues its down- 
ward movement without reliounding and without again becom- 
ing loose in the flask. 

Design 

The design of a machine cai)able of i)roducing the re- 
sults noted in the preceding paragraphs has been accomplished 
only by overcoming many obstacles. The chief difficulties en- 
countered have been the unpacking forces on the sand, and 
the irregularity of action. L'npacking forces on the sand are 
produced at two ditTerent ])(_)ints in the cycle of operation. 

1st. At llie rebound after the striking blow. (This has 
already been covered in preceding paragraphs.) 

2nd. At the top of the stroke. 

If, when the air is cut off at the top of the stroke, the pis- 
ton, tabic and flask decelerate more rapidly than gravity de- 
mands, then the sand will tend to decelerate less rapidly than 
the flask, and the result wall be a tendency of the sand to move 
upward in the flask. ])roducing on the sand an unpacking force 
which will partially destroy the ramming that has already been 
accomplished. Any mechanical defect which causes the pis- 
ton to be retarded unduly after the air has been cut off, will 
produce this result. A tight piston, either thru poor fitting 
or binding, will produce this trouble. 




Fig. 24. 

Figures 24, 25 and 26 show the result of tests wdiich will in- 
dicate the existence of an. unpacking force, either at the top 



38 Foundry Moulding Machines and Pattern Equipment 



or at the bottom of the stroke, aiul which will serve the furth- 
er purpose of indicating any irregularity which might be pre>- 
ent in the action of the machine. Any of these defects would 
show in the test curve of the machine, and should, of course, 
be investigated and eliminated. l-"igures 25 'and 26 show, re- 
spectively, a machine working properly and one working irregu- 
larly. 

Indicator card diagrams taken on foundry moulding ma- 
chines may seem, at first sight, to be rather out of place, but 
by the aid of these cards all of the guess work in regard to the 



"^ 




















' V 


"T" 


"T" 


"T" 


IT 


T 


V 


V 


V V 


"X 



Fig. 25. 



~T~^v \^~^^ 


^^^^T' 


"V \r 



Fig 26. 

setting ot valves, as well as the design of valves, can be elimin- 
ated. In correcting difficulties existing in the operation of the 
machine, the indicator cards are used in much the same way 
as those taken on a Corliss engine — a study of the card reveal- 
ing the difficulty and a subsequent card showing its elimination. 
There are adjustments necessary on a jolt machine in a studv 
of which the indicator cards are of valuable assistance. The 
length of stroke, the force of blow, and the amount of com- 
pression are the variable features. The factors afi^ecting 
these adjustments are as follows: .Size of the flask and 
])attern. grade of sand, nioistiu'e of sand, the bond of the 



Thfory of Jolt Ramming 39 



sand, the density to be attained, and the metal to be poured 
One should not get the false impression than an indicator card 
is necessary every time one of these factors is changed. On 
the contrary, the indicator cards are never used in the found- 
ry where trial settings quickly bring the proper results. The 
use of the indicator cards is confined to those who are mak- 
ing a laboratory study of the action of the machine, with a 
view of improving the machine, or of solving the extremely 
difficult cases which are not liable to be quickly solved by the 
guess method. They are also used to secure uniformity in 
manufacture. 

Summing up tlie jolt ramming machine, the jolt operation 
is fundamentally, basic and important. It substitutes machine 
power for hand power in performing a large portion of the 
work done on each mould, and means an even more import- 
ant difi'erence in the quality of the castings produced; due, 
however, to the fact that its achantages cannot be utilized to 
the fullest extent when the subse(|uent operations are perform- 
ed by hand, it becomes of the utmost importance to supple- 
ment jolt ramming with machine operations for the remain- 
ing step.^ in making a mould. The ste])s in the operation are 
as follows : 

1. jolt Ramming. 

2. iUitting Ott. 

.S. Rolling over (if necessary). 
4. Drawing the Pattern. 

The most advantageous maciiine. of course, is one which 
performs al! of these oiterations. 



40 



Foundry Moulding Machines and Pattern Equipment 




Fig. 27. A lypical Moulding Machine of the Roll Over .lolt Type. 



CHAPTER III 
Roll Over Jolt Moulding Machine 

The Roll Over Jolt Moulding ^lachine performs the 
three most fundamental operations in making a mould. It 
jolt rams the sand, rolls the mould over and draws the pat- 
tern, all by machine power, thus eliminating practically all of 
the hand work in connection with the making of a mould. 

In considering the construction and operation of the ma- 
chine, the subject naturally divides itself into three main head- 
ings, viz.. 

1. Jolting. 2. Rolling Over. 

3. Pattern Drawing. 

Each of these divisions can be still further subdivided into 
the subjects of operation of the machine and construction of 
the machine. In taking up each of these subdivisions, in or- 
der, we have first 

Jolting Operation 

The jolting mechanism, as built into the Roll Over Ma- 
chine, is very similar to that of the Plain Jolt Machine, which 
will be described in detail in Chapter VIII. The essential 
parts consist of a cylinder and a piston supporting a table, and a 
valve for the proper control of the air to secure the jolting mo- 
tion. Alany refinements are worked into the parts, such as liners 
in the cylinder, special oil grooves and oiling devices on the 
piston, special striking j)ads, safety limit stops, and valves of 
various designs, ranging from a simple sleeve valve to special 
valves designed and used for this ])urpose only. 

The jolting operation introduces severe strains in all parts 
of the machine and necessitates types of construction which 
would not otherwise be necessary. It also necessitates steel 
parts in some cases where otherwise cast iron would be sufifi- 
cient. Ill Figure 27 the jolting cylinder is in the center of 
the machine with the jolt valve to the left of it. In Figure 28 
the jolting mechanism is at the left. In Figure 29 the jolting 
mechanism is at the right side of the machine. 



42 



Foundry Moulding Macliini-s and Pattern Equipment 




Fig. 28. An Air Operated Roll 
Over Jolt Moulding Machine. 



The time re(|uired for hand ramming is approximately 
50 per cent of the total time required in floor moulding, and the 
jolt ramming feature of the machine practically eliminates this 
time, as the machine will jolt ram the mould in from 5 to 30 
seconds, and it can he "hutted off" in less than a minute on 
medium size moulds. The advantage of the lime saved is 
important, hut it is not the only benefit. The bettering of 
the quality of the castings obtained is a direct consequence of 
the uniformity of the jolt ramming operation. This applies 
to the accuracy of the shape of the casting as well as to the 
accuracy of reproduction. 



Roll Over Jolt Moulding Machine 43 



Roll Over Operation 

The roll over operation saves a large amount of time on 
each mould, although it does not contribute directly toward 
the production of a higher quality of casting. The saving 
in time, as compared to rolling over by the crane, is due to 
the following f actt~>rs : 

1. There is no waiting for the crane. 

2. The clamps and wedges used ni nilling over arc al- 
ways accessible, since they are always in the same 
])lace and the workmen have standardized their 
method of operation. This is contrasted with floor 
moulding, where each mould is rolled o\er on a new 
location and clamps and wedges must be moved 
froni p^'icc to ])lace as demanded. 

3. Standardized clamps for bottom boards require less 
time and are adopted as a part of the machine equip- 
ment, whereas they woubl not be standardized for 
floor work. 

4. The actual speed of rolling over is greater, due to the 
stability and steadiness of the machine. 

5. A suitable place for the rolled over mould is always 
available on the machine, whereas in floor moulding 
a portion of the floor must lie leveled off for each 
mould. 

The roll over operation is accomplished in the different 
designs of machines by various methods, based upon various 
mechanical principles. The machine illustrated in Figure 23 
rolls about a center located in the center of the machine at the 
highest point. Two arms reach down inside of the vertical 
members, extending thence horizontally to the left, where the 
pattern plate and flask are mounted. The roll over power is 
developed by an air operated cylinder which pulls down on a 
lug extending to the right from the roll over center, and in 
this way rolls the pattern and flask upward and over until the 
tiask is directly over the leveling device seen at the extreme 
right of the photograph. It is readily seen that the principle 



44 



Foundry Moulding Machinfs and Pattern Equipment 



employed is that of a lever having a force applied on one 
end and the weight acting on the other. 

The- machine illustrated in h'igvn'e 29 operates on the same 
general principle, and is shown with the table in a partly raised 
and rolled over position. In this case, however, the axis of 
rotation is on a line which is about at the floor level. An aux- 
iliary axis of rotation is located at the end of the movable arms, 
and the table rotates about this axis also. 




Fig. 29. The Mould is Finished and the Table is Returning 
to its Original Position. 

The machine illustrated in I'ii^urc 31 rolls over about the 
center of gravity of the nuiuld. The center of rotation is 
the trunnion shown at the extreme left of the machine. 

The machine illustrated on page 40 also rolls over about 
the centei of gravity of the mould. The force is "developed 



Roll Over Jolt Moulding Machine 



4,1 



by the cylinder shown hi the right foreground near the bot- 
tom of the machine, and is transmitted to the trmmions sup- 
porting the roll over table, causing them to rise. As the table 
rises it automatically rolls over before it reaches the top of its 
stroke. This rotation takes "place about the approximate cen- 
ter of gravity of the mould. 

The methods of operating some of the typical types of 
roll over machines are as follows : 

The machine illustrated in l-'igure 28 is controlled by the 
valves in the center foreground. The table is shown in the 
jolting position at the left, and is ready for the pattern to be 
placed upon it. After the pattern has been placed on the 
table, the flask is placed on the pattern plate, filled with sand 
and jolt rammed by the action of an air cylinder. The mould 
is then rolled over. This is accomplished by a piston pulling 
down on the lug which is shown extending to the right and 
upward from the center support of the machine, and causes 
the table at the other end of the lever to roll over. As the 
table leaves the horizontal position at the beginning of its roll 

over movement, the 
pattern is automat- 
ically locked to the 
roll over table by 
an air operated de- 
vice. The opening 
of another valve 
causes the piston 
ill the cylinder 
shown at the lower 
right hand corner 
of the illustration, 
to r i s e, carrying 
with it the four 
leveling pins, which 
are shown. These 
pins are air oper- 
ated and take up 




Fig. 30. Showing Clearly the Method of 
Pnttern Mounting Employed. 



46 



Foundry Moulding Machines and Pattern Equipment 



any irregularities in tlic thickness of the liottom hoard, 
after v. hich they are locked and the clamps are removed 
from tin; flask, allowing the flask to he supported on its 
bottom board by the leveling pins. The leveling table is 
now dropped vertically downward, leaving the pattern attached 
to the roll over table, which is rolled back to its original posi- 
tion at the left, ready for the making of the next mould. 




Fig. 31. A Machine with Hand Roll Over and Power Jolt Mechanism. 

Ano'her tv]:)ical roll over machine is shown on page 40. 
The metiiod of making a drag mould on such a machine is as 
follows : 

The i)altern is assumed to l)c mounted on a plate with 
suitable means for fastening to the roll over table of the ma- 
chine which is shown in the illustration at the upper left hand 
side. The flask is placed around the pattern, filled with sand, 
and jolt rammed. While jolt ramming, the sand is spread 
from the center to the edges of the flask, so that the butting 
off operation can l)e immediately and c|uickly performed. The 



Roll Over Jolt Moulding Machine 47 

bottom board is next bedded on and clamped to the mould, 
after which the mould is rolled over by air power operating a 
piston in the cylinder, shown at the lower right hand corner 
in the illustration on page 40. This motion is transmitted to 
the trunnions supporting the roll over table. As these trun- 
nions rise vertically, the table rises with them and a pair of 
chains, whicli are coiled about the semi-circular ends of the 
table, retard the movement of one side of the table, causing it 
to roll o\er. The le\eling car is then pushed underneath the 
roll over table, the table lowered tmtil the bottom board de- 
presses each of the pins a slight amoimt. the pins are locked 
and the clamps are removed, leaving the weight of the flask 
supported by the leveling car. and the pattern e(iuipment sup- 
ported by the roll over table. .\ided by the vibrator, the pat- 
tern is drawn vertically upward from the mould, which is then 
pushed cut on the leveling car. and the table is rolled back to 
its initial position, ready for the making of the next mould. 

The series of operations discussed for the two machines 
above are typical of the various types of Roll Over machines, 
and while minor differences in the operations will e.xist, due 
to differences of design and construction, yet the fimdamentals 
have been stated above. It is well to bear in mind that these 
machin'.'s have three major functions. 

1. The Jolting of the ^lonld. 

2. Rolling it over. 

3. Drawing the jiattern. 

Roll Over Construction 

The construction of the various parts of the roll over ap- 
paratus varies, of course, as widely as the methods employed. 
Some factors are, however, common to all of the methods. 
These are as follows : 

1. The action of the jolting feature of the machine de- 
mands heavy, strong parts which will have a long life 
under hard service. 



4S Foundry Moulding Machines and Pattfrn Equipnu-nt 



2. Since the machine operates in practically a shower of 
dirt and dust, all working parts must be protected from 
the action of the sand. Parts which cannot be to- 
tally enclosed in sand proof chambers should have ev- 
ery protection applied to them in the way of tight fit- 
ting bushings and proper design of parts so that sand 
will shed away from such places rather than accumu- 
late and wear in. 

3. 'J'he subsequent accuracy of the pattern drawing opera- 
tion depends absolutely upon the accuracy of the posi- 
tion of the roll over table at the completion of rolling 
over. It is most important, therefore, that the table 
shall be properly aligned, and that all working parts 
shall be carefully fitted so that great accuracy is 
obtained in the final position of the table. 

4. It is of importance that the parts of the roll over 
n.echanism should be so designed that they will require 
a minimum of air consumption for the operation, and 
so that undue weight will be avoided. 

I^attcrn Draw ing Operation 
This operation is very important from two viewpoints — 
it is a valuable source of time saving, both directly and indi- 
rectly, and it promotes, in a great measure, the higher quality 
of castings produced. The pattern drawing operation as accom- 
plished en the Roll Over type of machine, usually requires about 
5 to 30 seconds and when this is compared with the lengthy proc- 
ess employed in floor moulding, the gain in the direct time 
saved becomes at once apparent. Indirectly also, time is 
saved in that the pattern drawing operation is accurate to 
within an amount less than the taper of the pattern, so that 
the sand in the mould is left undamaged, and need not be 
slicked and patched. These useless operations of slicking and 
patching require a great amount of time when the pattern is 
drawn b}' hand, as there is always more or less damage done 
to the mould in that case. These operations of slicking and 
patching are a total loss of time, and the machine, in eliminat- 
ing them, saves time. 



Roll Over Jolt Moulding Machine 49 

'JMic method of accomplishing the pattern draw varies in 
the different designs of machines. It is immaterial whether 
the roll over ta])le is moved upward away from the leveling 
tahle. or whether the leveling table is moved downward from 
the roll over table — the result accomplished is the same. In 
all cases the pattern is supi)ort('d bv the roll over table and 
the mould must l)e supported b\ the leveling table, which is 
either movable or stationary, and is provided with some means 
of equalizing the variations or inequalities of the bottom board. 
Ordinary wedges or depressable pins are commonly u.sed for 
this purpose. 

The machine illustrated on page 40 draws the pattern 
by lifting it upward from the flask. The machines illustrated 
in Figures 28. ,^1 and M all draw the pattern by lowering the 
mould away from the stationary pattern. 

The principal points of interest are not in the method of 
accomplishing the movement, but rather in the accuracv with 
which the roll over table is held at right angles to the line of 
pattern draw, and in the accuracy with which the flask is 
brought to exact right angles with the line of pattern draw be- 
fore its weight is released from the roll over table and 
allowed to rest on the leveling table. One of the greatest diffi- 
culties is in deflection of the roll over table or of the leveling 
device. If, when the mould is released from the roll over 
table, the decrease in weight supported by it causes the table 
to spring slightly, the pattern will move in the sand, and will 
break up the mould before the pattern draw is even started. 
The same conditions will exist if the weight of the flask causes 
the leveling table to deflect, for if the pattern, attached to the 
roll over table, remains stationary and the mould should tip 
slightly the result wotild be a damaged mould. It is essential 
that the pattern be moved in a straight line, and the accuracy 
of the straight line motion is necessarily destroyed by any 
looseness in the fit of the bushings located in any of the mem- 
bers causing this motion. Accordingly, too much care cannot 
be taken with the design of bushings and bearings and with 
the accuracv with which thev are fitted. 



iiO 



Foundry Moulding Machines and Pattern Equipment 



The question of removing the finished mould from the ma- 
chine is usually considered in the design of the leveling tahle. 
In some cases the leveling table is provided with wheels and is 
run out from under the roll o\er table. This method is used 
in the niachine illustrated on page 40. In other cases, such 




Fig. 32. A Portable Roll Over Jolt Machine for Small Moulds. 



as the one illustrated in I'igtu't' 2S. tlie leveling; table remains 
stationary, and the roll over table returns to its original posi- 
tion, far enough removed from the leveling table position to 
allow the crane to take away the finished mould witliotit inter- 
fering with the operation of making the next mould. 



Roll Over Jolt Moulding Machine 51 

The advantages of machine pattern draw, as contrasted to 
hand pattern (h'aw are far reaching, extending in fact from 
the foundry all the way to the niacliine .^hou and to the as- 
sembly floor where the casting is finally used, and also even 
to the Treasurer's Department which no longer pays for over- 
weight castings. 'J'he j)attern is drawn in a])proximately 5 to 
30 seconds and this is in contrast to the old method of drawing 
a pattern where it iinist first be rapped, which damages it 
seriously, and which w ill damage the mould seriously before the 
jiattern is drawn. 

Machine Moukicd Castinirs 

Hand made castings vary from 5 per cent to 15 per cent in 
weight with corresponding variation in shape, whereas, machine 
moulded castings are identical as to weight and shape. In rough 
work, where great accuracy of shape is not a requirement of the 
parts, the variation in hand made castings is not a serious det- 
riment to their use. On the other hand, the reiiuirements for 
certain grades of castings are so exact that hand made castings 
do not measure up to the recjuired sjiecifications. and in such 
cases the uniformitv of machine castings is of greater import- 
ance. The outstanding examples of this latter class of cast- 
ings are those used in the automotive industry. As a rule, 
these castings are used by the thousands and the machine shops 
are specially equipped for the handling of each casting, with 
jigs and tools designed for it and with piece wor'-c lates set 
and procedure systemized to the last degree. In such cases 
a slight additional amount of metal here or there will seriously 
interfere with the use of the accurately fitting jigs, and will 
decrease the speed of the workman who is on a piece-work 
rate. Small metal allowances are also the rule, as for in- 
stance, in the embloc cylinders which have usually a 3/16 
thickne-s of wall and 3/16 thickness of water jacket. The 
variation allowed is very minute and the overall allov/ances of 
variation in the castings are always so small as to be neg- 
ligible. 



Foundry Moulding Machines and Pattrrn Equipment 



The Making of a Drag Mould on the Floor Contrasted 
with the Roll Over Jolt Moulding Machine 

Below is set forth a detailed comparison between the 
making of a mould by hand on the floor, and on the Roll Over 
type of machine. In comparing the operations, the viewpoint 
in mind should be the amount of physical labor necessary to 
perform each operation, the amoiuit of time consumed, and 
the quality of the work done. 



Floor 

T\\Q Pattern Plate 
A flat reinforced pattern 
plate of suitable size is placed 
on a leveled portion of the 
foundry floor. 

Pattern 

^Ihe drag half of the pat- 
tern, asswmed in this case to 
be a split pattern, is laid on 
the board in the location that 
is desired. 

Flask 

The flask is placed on the 
pattern plate surrounding the 
pattern and in such relation to 
the pattern that there will be 
sufficient room for gating and 
sufficient sand thickness be- 
tween the pattern and the flask. 

Facing Sand 

On all heavy and high grade 
work, facing sand is used ; oth- 
erwise moulding sand is rid- 
dled onto the pattern. 



Machine 



Pattern 

The pattern, mounted on 
the pattern plate, is attached 
to the roll-over table of the 
machine. 

Flask 

'J1ic flask is placed on the 
pattern plate, the pins locat- 
ing it. 



Facing Sand 

On all heavy and high grade 
work, facing sand is used ; 
otherwise moulding sand is 
riddled onto the pattern. 



Roll Over Jolt Moulding Machine 



53 



Floor 

Sand 
Sand is put inlo the llask 
either by hand shovelinj^'. l)y 
grab buckets, or from an over- 
head l)in. 'I he method em- 
ployed depends on the size of 
the ti;i>k and on shop equip- 
ment. 

Ramming 

The mould is rammed either 
by hand or by a pneumatic 
rannner. whicli is substantial- 
ly the same size as the hand 
ramnu'r. but is operated by a 
'^mrdl air cylinder. This oper- 
ation consumes approximately 
50% of the total moulding 
time, and introduces the vari- 
able luuuan factor into the 
density of the ranuned sand. 
This operation also constitutes 
a large part of tin- hard physi- 
cal labor of the foimdrv and 
contributes a large share to- 
wards making it such an im- 
4^1easant ]')lace in which to 
work-. 

Striking Off 

Steel bars are better prac- 
tice than wooden ones for 
striking oflf the flask. .\ wide 
strike off bar has been found 
to be very advantageous on 
small and medium size flasks. 



Machine 

Sand 

."^and is ])ut into the flask 
eiilier 1)\- hand shoveling, by 
giab buckets, or from an over- 
head bin. The method em- 
ployed de])ends upon the size 
oi" the flask and on shop 
e(|nipment. 

Ramming 

The mould is rannued by 
jolting, accomplished by power 
and controlled by a valve. The 
butting otT is done bv hand. 



Striking Off 

Steel bars are better prac- 
tice than wooden ones for 
striking oiiP the flask. A wide 
strike ofi:' bar has been found 
to be very advantageous on 
small ;ind medium size flasks. 



Foundry Moulding Machines and Pattern Equipment 



Floor 

Bottom Board 

The bottom board is fitted 
into place by scattering a hand- 
ful or two of sand over the 
surface of the mould and 
working the board back and 
forth over it to obtain a uni- 
form bearing at all points. 

Clamping the 
Bottom Board 

"C" clamps are employed, 
being tightened by means of 
wedges. The clamps must be 
moved from one location to 
another on the floor as the 
moulds are put up. 

Rolling Over 

The rolling over of a mould 
involves the use of a crane 
on mediimi and large size 
moulds, and frequently calls 
for the assistance of several 
other men besides the moulder 
and helpers working on the 
mould being rolled over. The 
danger of a damaged mould, 
due to the shifting of the bot- 
tom board, is always present. 
Delays while waiting for the 
crane, or for other workmen, 
are common. Extra space is 
always required in an already 
busy foundry. Hiis nuist be 
cleared especially for the pur- 



Machine 

Bottom Board 

'Jlie bottom board is fitted 
into place by scattering a 
handful or two of sand over 
the surface of the mould and 
working the board back and 
forth over it to obtain a uni- 
form bearing at ;ill points. 

Clamping the 
Bottom Board 

Either "C" clamps or spe- 
cial clamps are used. 



Rolling Over 

Power applied to the ma- 
chine automatically rolls the 
mould over. 



Roll Over Jolt Moulding, Machine 



55 



Floor 

pose. After rolling over, the 
bottom board is undamped. 

Drawing the Pattern 

The pattern is first rapped 
by means of a rapping pin 
inserted into the rapping plate 
which has been built into the 
pattern for the purpo.^e. Tiie 
pin is rapped back and forth 
and from left to right with a 
hammer or mallet, loosening 
the pattern in the sand so 
that it may be withdrawn with 
as little damage to the mould 
as possible. The lifting han- 
dle is then inserted in the plate 
provided in the pattern and the 
pattern drawn as nearly 
straight upward as possible, 
taking care not to damage the 
mould any more than can be 
avoided. 

Slicking and Patching 

Some damage is invariably 
done in drawing the pattern, 
and the moulder now slicks 
over these places and patches 
up any broken corners or sur- 
faces. These two operations 
are very detrimental to the 
shape and size of the casting, 
and also impede the escape 
of the gases at the time of 
pouring. In addition, this op- 



Machine 



Drawing the Pattern 

The vibrator is placed in 
operation and the machine 
draws the pattern. 



SHckine and Patching 
Not required. 



56 



Foundry Moulding Machines and Pattern Equipment 



Floor 

cralioii frc(|ucntly consumes 
mure time llian any dihcr one 
operation connected with mak- 
ing- moulds, and as the time 
tluis sj)enl is a total loss, the 
inefficiency of such a meth- 
od is |»reat. 

Prepariiiir \o\ 
the Next Mould 



Machine 



Preparing for 
the Next Alould 



Tlie pattern ])late. wed!.';es. TIk- machine upon complet- 

clamps. ]);itterns. rajipiui;- and ini^ one mould, is re.ady for the 
slicking;' tools nni^t now all he makin,c^ of the next, 
moved to the next locrition on 
the foiuKlrv floor. This in- 
volves a lari^e aniomit ol time 
spent in levelini;' the place on 
the tloor u])on which to woi-k 
and in movin".;' small tools and 
e(|nipment : all of this time is 
non-productive. 



Roll Over jolt Moulding Machine 




oS 



Foundry Moulding Machines and Pattern Equipment 




1?TWlnaii a- 



Fig. 34. A large Roll-Over Jolt-Moulding Machine, with Foundations 

Cut Away to Show the Construction Underneath 

the Foundry Floor. 



CHAPTER IV 

Roll Over Jolt Moulding Machines For 
Large Size Molds 

Large moulds, as referred to in this chapter, will be con- 
sidered to include moulds of from 3,000 to 20,000 pounds in 
weight. Manufacturers commonly rate their machines in terms 
of the maximum load and the maximum flask sizes. Flasks 
ranging in length from 72" to 150" are usually regarded as of 
a size requiring large Roll Over Machines. 

The principles of construction and operation of the large 
Roll Over Jolt Machines have already been covered in the 
preceding chapter, and the reader is referred there for details. 

The handling of the large size moulds with their attend- 
ant heavy equipment brings up the question of the crane 
equipment necessary for handling of patterns, flasks, bottom 
boards, moulds, setting cores and closing moulds. The use of 
a crane for so many operations would seem to necessitate an 
exceptional amount of crane service but when the number of 
moulds produced per day is considered, it will be seen that a 
large machine requires about the same amount of crane atten- 
tion as a medium size machine. The machine does not add to 
the demands upon the crane, but rather lessens them. For 
instance, a foundry may be employing a number of floor mould- 
ers, all being served by the one crane. In changing over to 
machine moulding, say, for example, two moulding machines 
would be used to put up the same total number of moulds, using 
fewer men but the same crane. This crane would now be 
be relieved of rolling the moulds over and of drawing the pat- 
terns, these operations being performed by the machines. 

The output of large machines, measured in tonnage pro- 
duced, does not vary greatly from the output of medium size 
machines as the greater weight per casting is just about evenly 
offset by the smaller number of moulds produced. When the 
figure is reduced to a "tons per man" basis, it increases some- 
what with the size of the machine used. 



(in 



Foundry Mnuldiivi Mo.chinrs and J-c.ltnn liijui pw.riil 




Fig. 35. Tunnel Segment Mould — 
Lower or Drag Half — Made on a Rull- 
0\cr Jolt Machine. In the view shown 
above, the machine is roiiini: over the mould 
after it has been jolted and bottf)m board 
clamped. 

.\fter the rolline-(j\er operation is com- 
pleted, the mould is lowered on the run-out 
car, shown in the rear, clamps rcmo\-cd and 
pattern drawn from the mould. 

'The lower \ iew shows the completed 
lower half or drair mould before the cores 




Roll Over Jolt Moulding Machiiifs for Large Size Moulds 



C.l 



Fig. 36. Tunnel Seg- 
ment Mould — Upper 
Half or Cope — Made on 
a 42 "xJ)?" plain jolt-moulJ- 
ing machine. 




Tunnel Segment Casting 
Weighing 1500 Pounds. 

Used in making tunnel linings for 
the New ^'ork subway system. 




PRODUCTION 



Method of Moulding 


No. 
Men 


Hours 


Quan. 
Moulds 


% 
Increase 


Without Machine 


2 


<» 


7 




Cope— 42 ".\t)7 " Plain [oh 




9 


14 




Drag— 42 "xD?" Plain Jolt 


2 


100% 


Cope— 42"x97" Plain Jolt 

Drae— 42"xl('6" R. 0. Jolt 


« 


9 


*141 


570% 



* With sand conveying system. 



Foundry Moulding Machines and Pattern Kquipmenl 



t^-J? 



'm 5 





Fig. 37. Railway Truck Frame Steel Casting— Weight 470 Pounds. 

The standardization of railway equipment has resulted in large quantity pro- 
duction of the various castings. 

The production figures given below are based on using two machines of the 
Roll-Over Jolt type — one for the lower or drag half and the other for the upper or 
cope half of the mould. 



PRODUCTION 



Method of Moulding 


No. 
Men 


Hours 


Quan. 
Moulds 


% 
Increase 


Without Machine 




9 


15 










Cope— 42"x97" Plain Jolt 

Drag— 42"x97" Plain Jolt 


5 


9 


*40 


166% 


Cope— 42"xl06" R. 0. Jolt 

Drag— 42 "x 106' R. 0. Jolt 


. . . . 7 


9 


*120 


470% 



*\\ ith sanJ conveying system. 



Roll Over Jolt Moulding Machines for Large Size Moulds 



63 



The shipbuilding industry has 
not attained the quantity pro- 
duction shown on the preceding 
pages, yet a very great saving can 
be made by the use of moulding 
machinery on smaller quantity 
production as is shown in the 
following tabulations. 



The production figures given 
below are based on making the 
cope and drag moulds on the 
same machine. 




Fig. 38. Marine Engine Cylinder 
Head — Weight 2400 pounds. 





PRODUCTION 








Method of Moulding 


No. 
Men 


Hours 


Quan. 
Moulds 


% 

Increase 


Without Machine 


4 


9 


1 




Cope— 72"x72" Plain Jolt. . . 
Drag— 72''x72" Plain Jolt. . 


'.'.'.'.'.'.'.'... 4 


9 


2 


100% 


Cope— 60 "x92"R.O. Jolt.. 
Drag— 60"x92" R. 0. Jolt. . 


.'.'.'.'.'.'.'.'.. 4 


9 


3 


200% 



«4 



Foundry Moulding Machini-s and Pattern Equipment 




Fia. 39 



Marine Engine Column — Weight 4000 pounds. 

\\ here the quantity of castings required from one pattern is not sutiiciont 
for continuous production, or even for a full da\'s produciicjii. an\- number of 
different patterns can be used during the da}'. The clianging of the pattern on 
the Roll-Over Jolt-Mouldinp Machine requires onh- a few minutes ot tin;e. 



The production figures given below are based on making the cope and drag 
moulds on the same machine. . 



PRODUCTION 



Method of Moulding 


No. 
Men 


Hours 


Quan. 

Moulds 


% 

1. 1 crease 


Without Machine 


4 


() 


1 




Cope — 42"x<)7" Plain ]o\\. 




{) 


•) 




Drag— 42"x97" Plain Jolt 


4 


100% 


Cope— (id "xl .■)()" R. O. Jolt . . . 
Drag— ()()"xl.")()" R. (). Jolt. 


4 


<» 


.") 


4(M)% 



Roll Over Jolt Moulding Machines for Large Size Moulds 



m 



A large number of machine tool 
castings are adaptable for machine 
moulding, particularly on the Roil- 
Over Jolt type of machine. 

In some instances, wliere a 
casting does not readily lend itself 
to machine moulding, a slight 
change can be made in the design 
without impairing its utility or 
strength. thereb\- making it 
possible to mould on machines. 



/<»■ 






'>*Z7e9 


/2" 






305-m"v 






T 






^.W^ 




/ 1 


^^5( ) 




{ o 


U'^^ 


^ 


. — .1 




Fig. 40 



Planer Housing lasting — Weight 
5000 Pounds 



The production figures gi\en below are based on making the cope and drag 
moulds on the same machine. 



PRODUCTION 



Method of Mouldin? 


No. 
.Men 


Hours 


Quan. 
Moulds 


T ^° 
Increase 


Without Machine 


4 


1» 


1 




Cope— 72"x72" Plain Jolt 

Drag— 72"x72" Plain Jolt 


4 


<» 


•> 


100% 


Cope— 66"xl.')()" R. O. Jolt 

Drag— 66"xl.'J0" R. 0. Jolt 


.... 4 


1< 


.") 


400% 



66 



Foundry Moulding Machines and Paltern Equipment 



Milling Machine Column. 

Weight of Casting — 

700 Pounds 

A 4o"x72" Roll-Over Jolt-Moulding 
Machine made both the upper or cope 
half and lower or drag half of the 
mould for producing this casting. 



The production figures given below 
are based on making the cope and 
drag moulds on the same machine. 




Fig. 41 



PRODUCTION 



Method of Moulding 


No. 
Men 


Hours 


■ Quan. 
Moulds 


Increase 


Without Machine 


4 


9 


4 










Cope— 54"x66" Plain Jolt 

Drag — 54"x66" Plain Jolt 


4 


9 


8 


100% 








Cope— 45 ''x72 " R. 0. Jolt . . . 




9 


14 




Drag— 4.5 "x7J" R. 0. Jolt 


4 


2.50% 



Roll Over Jolt Moulding Machines for Large Size Moulds 



(u 



A Milling Machine Base Cast- 
ing made on a Roll-Over Jolt- 
Moulding Machine having an over- 
all flask capacit}' of 45" in width by 
72" in length. This machine is cap- 
able of jolting and rolling over half 
moulds up to 4, (KM) pounds in weight. 



i_ 




& 


1_J 

^ 


n 


^ 


1 X ) 




cpr 


fe 


u 




-r^ 


S4 
" 872 •»« 


» 








^u 



Fig. 42 
Weight of Casting^l040 Pounds. 



The production figures given below are based 'm makiui; the cope and dra^r 
moulds on the same machine. 



PRODUCTION 



Method of Moulding 


No. 
Men 


Hours 


Quan. 
Moulds 


% 

Increase 


Without Machine 


.... 3 


9 


4 










Cope— 54''x66" Plain Jolt 

Drag— .54"x66" Plain Jolt 


3 


9 


S 


100% 


Cope— 45 "x7''" R. O. Jolt. . . 




9 


18 




Drag— 45"x72" R. 0. Jolt 


3 


350% . 



68 



Foundry Moulding Ma< hinrs and Paftrrn Eijuipment 












^^■/f 


"t 


-^ , 










^ -' 


1 






44" 




5" --- 
1 27'"*'*"' 


\ 










-^^ij/e 










' 


/^ 




^l 
















I 
















1 














t 






/ 



J 




\, 'ifri i'»'l»w>ii*-ni>iOii««l»ii»iiii'»^-..^^. -ti^tMa^i^ii^^. 



Fig. 43 



Milling Machine Table Casting — Weight 500 Pounds. 

A 4.'j".\72" Roll-Over Jolt-Moulding Machine made the moulds for producing 
this casting. Its simplicity in design makes possible a large production by hand 
moulding, yet a very large increase has been obtained by machine moulding, as 
noted in the following tabulation. 

The production figures gi\cn below arc based on making the cope and drag 
moulds on the same machine. 



PRODUCTION 



Method of Moiildinp 


No. 
Men 


Hours 


Quan. 
Moulds 


% 

Increase 


Without Machine. . . 


3 


<> 


11 










Cope — 42 ".\();)" Plain Jolt 




i) 


IS 




Drag— 42"xfi()" Plain Jolt 


W 


64% 


Cope— 4.") "x72 " R. (). Jolt 

Drag— 4.") "x72 " R. (). "jolt 


... . 3 


9 


32 


190% 







Roll Over Jolt Moulding Machines {or Large Moulds ()0 




Fig. 44. A Large Roll Over Machine Used in the Core Room. 



70 



Foundry Moulding Machines and Paltrrn F.'juiptr.rnt 




Fig. 45 A Roll Over Jolt Moulding Machine Suitable for Making 
Medium Size Molds. 



CHAPTER V 

Roll Over Jolt Moulding Machines For 
Medium Size Moulds 

Medium size moulds are considered to include those rang- 
ing in weight from 1,000 to 3.000 pounds, and from 44" to 
64" in length. Such a class of work requires a crane for han- 
dling flasks and moulds, hut the hottom board and cores can 
usually be handled by hand. The machine illustrated on page 
70 is a machine l)eli)nging to the class which produces medium 
size movilds. 

Medium size moulds, being of moderate weight, demand 
a production of a large number of moulds per day, in order 
to keep the figure of "pounds of iron per man per day" as 
high as it should be. Since high production is important, it 
is advisable to touch on a few points in regard to the methods 
of producing the cope and drag moulds. 1liis is solved in a 
wider variety of ways on this type of machine than on any 
other. The simplest method is to produce drag moulds in 
the forenoon, change patterns in the middle of the day, and 
then to produce cope moulds to go with the drags. The 
disadvantage of this method is that production is limited, and 
that the drag moulds, which remain on the floor for several 
liours before being closed, are liable to physical damage, set- 
tling dust and drying out. It is the practice in some shops 
to avoid the undesirable feature of having drag moulds sit on 
the floor for several hours by making six or eight drag moulds, 
changing patterns, making six or eight cope moulds and then 
repeating the cycle. This requires very rapid methods of 
changing patterns, or too much time will be lost in making 
the changes. The most obvious remedy, where larger pro- 
duction is desired, is the em})loyment of two Roll Over 
Machines, one producing copes, while the other produces drags. 
Hie drag moulds are then closed as rapidly as they are made, 
and a verv desirable ct)mpetition is established between the 



Foundry Mould inf, Mr.chiiifs and Pattern Equipment 



crews of the draj^- and c()])C' niachiiu's. and, at limes, between 
the coro setters and the machine crews. The utiHzatinn of 
the competitive spirit is an excellent aid to production. 

A variation of this method, in large quantity production, 
is the use of a Roll Over Machine for the dratjs and of a 
Stripper Machine for the copes. When using a Roll Over 
Machine for making copes, the crew operating the cope 
machine have a harder task than those operating the drag 
machine, on account of their having to form a gate in the 
cope, and also because of the frequent necessity of setting gag- 
gers in the cope. This condition is, however, reversed when 
a Stripping Plate Machine is employed for making the cope, 
as the crew operating the cope machine can then easily pro- 
duce n^oie moulds than the crew operating the Roll Over 
Machine, making drags. In fact, it has been found possible 
for a single Stripping Plate Machine to keep up with two 
Roll Over Machines making drags, and this unit of three 
machines provides a highly ef^cient disposition of men and 
machines, resulting in a high production. The competitive 
spirit which is introduced into the work can be used to good 
advantage. 

All the methods discussed thus far have dealt witli 
the mounting of one pattern, or at least of only one flask on 
a machine, using a machine of the proper capacity and size. 
An alternative method frequently employed is the use of a 
machine large enough to accommodate two moulds side by 
side, ''he machine shown in h'igure l.il ])r()duces both a cope 
and a drag half at each operation, since the cope and drag 
patterns are mounted side by side on the Roll Over Table. 
This same method is employed in conjunction with the Strip- 
ping Plate Machine. I'igure 132 illustrates tht nKumting of 
two dr;i'^ ]")attcrns side bv side on the table of the Roll ( )ver 
Jolt Moulding Machine. A small Stripping Plate Machine 
opei'atcs twice as fast as the Roll Over Machine and i)r()duces 
enough copes for all of the drags. 

There remains one other method which is sometimes 
employed as an aid to production when the pattern is symmet- 



Roll Over Jolt Moulding Machines for Medium Size Moulds T'.i 

rical about both center lines, that is. the center Hne joining 
the pins and the hne perpendicularly bisecting this line. The 
same pattern may then be used for making both cope and 
drag moulds. In some cases where one half of the gate is 
mounted on the plate, the mould becomes essentially non- 
symmetrical about the principal center line and requires care 
in closing, as the cope mcnild must he turned end for end 
before closing. In order to avoid the possibility of closing 
the mould improperly, it is best, in all cases, to endeavor 
to keep the pattern and gates symmetrical about both center 
lines. 




Fig. 46. A Medium Size Roll Over Machine. 



Foundry Moulding Machines and Pattern Equipment 




Fig. 47 



Automobile Cylinder with Upper Half of Crank Case 
cast en bloc— Made on a Roll-Over Jolt-]\IoulcHng Machine. 

This view shows the pattern drawn frtan the mould, 
which is deposited on the run-out car and ready for the 
crane to remove to the foundrv floor for setting the core. 

After sufficient drags ha\"e ])een made t(T begin core- 
setting, the drag pattern is remo\ed from the machine and 
the cope pattern substituted. 'I'his changing of pattern con- 
sinnes al)i)ut fi\e minutes in time, as only four l)()lts are 
used in securing it to the roll-o\ er table. 

Foundries producing these castings in large quantities 
find it advisable to tise two machines in producing the 
UK^uld — one to be used in making the cope half and the 
other the dratr half of the nmuld. 



Roll Over Jolt Moulding Machines for Medium Size Moulds "o 




Fig. 48 

Automobile Cylinder en bloc. Weight 175 Pounds. 

The production figures given below are based on making the cope and the 
drag on the same machine. 

PRODUCTION 

No. Quan. % 

Method of Moulding Men Hours Moulds Increase 

Without Machine 2 9 2 

Cope— 36"x4S" Plain Jolt ^ 

Drag— 36"x48" Plain jolt 2 9 4 100% 

Cope— 34"x64" R. O. Jolt ^ 

Drag-34"x64" R. O. Jolt 4 9 4S 1100% 



Foundry Moulding Machines and Pctlern Equipment 



An Automobile Truck Wheel 

Produced in a Steel 

Foundry. 

Beginning work in the morning, 
10 to 15 drags are made, permitting 
the core-setter to start work. The 
drag pattern is then removed from 
the machine and the cope half of the 
mould is made. Rotation in this 
manner makes possible the closing 
of the mould before the floor is com- 
pletely filled. 

If the quantity is sufficient, it is 
advisable to use two machines, one 
for the cope and one for the drag. 




Fig. 49 
Weight 240 Pounds. 



The production figures given below are based on making the cope and dras 
moulds on the same machine. 



PRODUCTION 



Method of Moulding 

Without Machine 

Cope— 42"x6()" Plain Jolt. 
Drag— 42"xti()" Plain Jolt. 

Cope— 34"x()4" R. O. Jolt. 
Drag— 34"x64" R. O. Jolt. 



No. 
Men 



Quan. % 

Hours Moulds Increase 



9 IS 100% 



45 400% 



Roll Over Jolt Moulding Machin es for Medium Size Moulds JJ, 



Remarkable progress is being made 
on tractor work and the large quantity 
of castings required makes machine 
moulding a necessity. 



A pair of 34"x64" Roll-Over Joh- 
Moulding Machines were used in 
obtaining the production noted below, 
one making the cope half and the other 
the drag half of the mould. 




Fig. 50 

Tractor Sprocket Wheel — 
Weight 115 Pounds. 



PRODUCTION 



Method of Moulding 


No. 
Men 


Hours 


Quan. 
Moulds 


Increase 


Without Machine 


6 


9 


30 




Cope— 36"x4S" Plain Jolt 

Drag— 36"x48" Plain Jolt 


'.'.'.. 6 


<) 


GO 
110 


100% 


Cope— 34"x64" R. 0. Jolt 

Drag— 34"x64" R. 0. Jolt 


8 


8 


208% 













78 



foundry Moulding Machines and Pattern Equipment 





Fig. 51 



The Upper Half of Liberty Motor Aluminum Crank Case — made 

on a 34''x70" Roll-Over Jolt-Moulding Machine. 

The large production noted in the tabulation below was obtained with a 
pair of these machines, one making the upper or cope half and the other the lower 
or drag half of the mould. 

Weight of Casting 100 Pounds. 
PRODUCTION 

No. Quan. % 

Method of Mouldinp Men Hours Moulds Increase 

Without Machine 8 9 1ft 

Cope— 42"x60"' Plain Jolt 

Drag— 42 "x60" Plain Jolt K 9 :V2 100% 

Cope— 34"x(70" R. O. Jolt 

Drag— .34"x70" R. O. Jolt S 9 102 540% 



Roll Over Jolt Moulding Machines for Medium Size Moulds 




Fig. 52. 
Weight 230 Pounds. 



Steel Casting of a Lower Ball Race for 6 Ton Armored Truck. 

Made on a 32''x54" Roll-Over Jolt-Moulding Machine. A dense and 
uniform casting is very essential in work of this kind. Loss from defective 
castings is reduced to a minimum by machine moulding, thus making a 
saving in labor and metal and also increasing the production. 



Production based on using one machine for both the cope and the drag half 
of the mould. 



PRODUCTION 



Method of Moulding 


No. 

Men 


Hours 


Quan. 
Moulds 


% 

Increase 


Without Machine 


3 


9 


20 




Cope— 24"x36" Plain Jolt 

Drag— 24"x36" Plain Jolt 


...'. 3 


9 


32 


60% 


Cope— 32"x54" R. 0. Jolt 

Drag— 32"x54" R. 0. Jolt 


'..'.'. 3 


9 


45 


125% 



so 



Foundry Moulding Machines and Pattern Equipment 



Milling Machine Drive Pulley. 



Weight of Casting 150 Pounds. 




Fig. 53 



Production based on using one macliine for both tiic cope and tlie drap half 
of the mould. 

PRODUCTION 



Method of Moulding 


No. 
Men 


Hours 


Quan. 
Moulds 


Vc 
Increase 


Without ^lachine. . . ... 


. . 3 


9 


20 










Cope— 24"x:}6" Plain Jolt 

Drag— 24"x36" Plain Jolt 


'.'.'.'. 3 


9 


32 


60% 


Cope— .32".x54" R. 0. Jolt 

Drag— 32"x-)4" R. 0. Jolt 


3 


9 


45 


125% 



Roll 



Over Jolt Muulding Marliiii,-s j<>r Maiium Sizr Moulds S^ 



Casting Used in the Shipbuilding 
Industry. 




L^<:^ 


!::;> 


v-^^ 




cZ^=r~ 


^^ 


1 


r^ 


.. 




J- 



Towing Chock. ^^ eight 
500 Pounds. 




Fig. 54 

Production based on using one maciiinc for both tiu- cope and the drag half 
of the mould. 

PRODUCTION 

fvjo Quan. % 

Me thod of Moulding Men Hours Moulds Increase 

Without Machine "^ _11__— 

Cope— 36"x48" Plain Jolt ,^(u 

Drag -36"x48" Plain Jolt 4 9 S _m)^_ 

Cope— 34"x64" R. O. Jolt .^c» 

Drap-34"x64" R. O. Jolt 4 9 jg_ ^"^/^ 



82 



Foundry Moulding Machines and Patti-rn Equipment 




Casting Used in the Ship- 
building Industry. 




Fig. 55 
Combination Mooring Timberhead. 



Production based on usiiit; one machine for both tlic cope and tlie drag half 
of the mould. 



PRODUCTION 



Method of Moulding 


No. 
Men 


Hours 


Quan. 
Moulds 


% 

Increase 


Without Machine 


4 


9 


5 




Cope— 42"x60" Plain Jolt 

Drag— 42"x60" Plain Jolt 


4 


9 


9 


80% 


Cope— 34"x64" R. 0. Jolt 
Drag— 34''x()4" R. 0. Jolt 


4 


It 


22 


340% 



Roll Over Jolt Moulding Machines for Medium Size Moulds 



H3 



Shipbuilding Industry 























=^=^ 






OASnUGa RBO'D 1 


MACHItrS UOUlDIIfG 1 


HAJfD MOTTLDINO 


3A7IWS 






Kama 


^Tunt 


R.O. 
Maoh. 


Out- 
Put 


Ho. 
Uen 


0o8t 

Eaoh 


Out- 
Put 


no. 

Man 


foet 
Eaoh 


TaluB 


H 


Uan 
Doya 




le" Bits - 


600 


46"x72" 
8 bz 


30 


4 


t .70 


2 


2 


t6.25 


$2730. 


86 


520 




Core 


2400 


32"x64" 


140 


S 


.066 


16 


1 


.376 


693. 








TOTtt 








6 






3 




3423. 


==— 


636 




9* Bite - B 


IBOO 


45"x7E" 
2 tx 


36 


4 


.60 


3 


2 


3.50 


5220. 


83 


992 




Oor« 


7000 


32''x64" 


140 


& 


.066 




36 


2 

4 


.33 


7000. 




1288 




6" Bit - A 


600 


34"x64'' 


40 


3 


.413 


6 


£ 


1.76 


802. 


76 


156 






lEOO 


E2"x37" 


160 


1 


.04 


25 


1 


.24 


240. 


63 


40 




TOTAL 








4 






3 




1042. 




196 




Mooring Rings 
Dwg. H-62 #4 


1200 
300 


34"x64" 


40 


4 


.526 


9 


6 


s.eo 


4462. 


86 


850 




Core ^d 
i'o 


2400 


E2"x37" 


lOO 


S 


.12 


18 


1 


.33 










TOTAL 














II 509 Z. 


J — LJ!!1 


J 



Fig. 56 



Tabulation showing production by machine and by hand moulding on a 
number of ship castings. The total value of saving by machine moulding on the 
quantity noted amounts to $16,359.00. 



The total amount of labor by hand moulding. 
The total amount of labor by machine moulding 

Saving in labor 



.3,767 man days 
. 691 " " 



3,076 " " 



Average percentage of saving. 



.81% 



S4 



Fouiidrv Moulding Machints and Pallt-rn Equipment 



Shipbuilding Industry 



CA3TIS03 RSJ'D VACHIira MOPLDIKO 


Hjun) 


MOULDING 


3AVIS8 


Rams Uach 


Out 
Put 


No 
Uan 


OOBt 

Bach 


Out 
Put 


HO 
Men 


Coat 
Gaoh 


Value 


« 


Uan Days 
Far Uo. 


Driving Coller 
fae" «la. ) 


32"xM* 


40 


2 


.26 


3 


1 


3.50 


3.24 


93 


294 


Windlan Side 


3£"t64" 


£4 


2 


.44 


3 


1 


3.60 


3.06 


87 


166 


Several Snail Bl- 

tcTs; Ash 5UE 

Baffle Pitta; Dis- 
charge Valve - 
Chest Liner 


32"x64" 

or 
2£"t37" 


40-60 

of any 
of 
these 


2 


.21 
to 
.26 


4 
to 
6 


2 


1.76 
to 
2.62 


1.54 88 
to to 
2.36 90 


620 



Fig. 57 



Total saving per month. 

Total saving in labor 

Average percentage of sa\ing . 



. . . ..1|;S,;i47.0() 

070 man days 

.89% 



CASTINGS BiSl'D 


MACHIUE MOULDIRG 


HAHD MOULDING 


SAVING 


None 


R.O. 
Mach 


Out 
Put 


Ho 
Men 


Cost 
Saoh 


Out 
Put 


No 
Men 


Cost 
Bach 


Value 


i 


Van Days 
Per Mo. 


Housing Slides 


34"x64" 


40 


3 


.41 


4 


1 


1.60 


1.09 


73 


182 


Winch Head 

(Cstg. 24" dla. Bot. 

( " 18" " top 


34"l64" 


40 


3 


.41 


2 


2 


6.26 


4.84 


92 


962 


Anchor Chain 
Stopper 


34"x64" 


12 


3 


1.38 


1 m 

1-2/3 
days 


2 


7.00 


6.62 


80 


338 



Fig. 58 



lotal saving per month. 

Total saving in labor 

Average percentai:e of saving. 



$S, 070.04 
I JV.'.A man days 

84% 



Roll Over Jolt Moulding Machines for Medium Size Moulds 



S5 




86 



Foundry Moulding Machines and Pattern Equipvient 




Roll Over Jolt Moulding Machines for Medium Size Moulds 



87 




88 



Foundry Moulding Machines and Pattern Equipment 




Roll Over J oil Moulding Machines for Medium Size Moulds 



89 




90 



Foundiy Moulding Machines and Pattern Equipment 




Roll Over Jolt Moulding Machines for Medium Size Moulds 



91 




92 



Foundry Moulding Machines and Pattern Equipment 




Fig. 66. A Small Roll Over Jolt Machine Showing the Foundation. 



CHAPTER VI 

Roll Over Jolt Moulding Machines for 
Small Moulds 

The good results produced from the use of Jolt Moulding 
Machines on the large and medium size work, creates a demand 
for a l«'lt Moulding Machine that will quickly handle the many 
small i)atterns adaptable to jolt moulding. The machine 
should be small, self contained and protected from sand and 
grit. It should not require a pit in which to set, nor should the 
falling sand from the flask obstruct its working. The different 
operations of the machine should be performed in the simplest 
manner possible and without consuming an excessive amount 
of time. Especially is this true of the operations other than 
the jolting of the mould, as when these operations are com- 
pared with the operations of a moulder making a mould on 
the floor, it is evident that he does not spend much time in 
clamping the bottom board onto the flask, or in the rolling 
over of the mould, and, therefore, these operations when 
performed on the machine and considered from the stand- 
point of time alone, require the utmost speed in the operation 
of the machine. However, there enters at this point an ele- 
ment not thus far considered, i.e., while the moulder when 
making the mould on the floor, can perform a few of the 
individual operations in the same time, or even faster than 
the machine, nevertheless, the performing of these operations 
throughout the entire day consumes the vitality and strength 
of the moulder, and it is a fact that in the latter part of 
the day his operations are neither as uniform nor as accurate 
and certainly are not nearly as speedy as they were at the 
beginning of the day's work; while the operations performed 
by machine power are constant throughout the entire day and 
demand very little effort on the part of the operator. 

There was a time, now past, when these most vital points 
did not require the consideration that must now be given them, 
for at that time there was an abundance of skilled manpower 



94 



Foundry Moulding Machines and Pat'ern Equipment 



available, workmen could be had to perform these tasks at 
a low rate of wages, and in order to secure a livelihood the 
workman produced a large day's work at the expense of break- 
ing down his health and strength. Conditions, however, have 
changed and those days have seemingly passed forever, as the 




Fig. 67. A Portable Roll Over Jolt Machine for Small Moulds. 



workman has come to a position where he is satisfied that 
he should produce the necessities of a livelihood without the 
hard work which in the past has been so necessary to maintain 
a satisfactory foundry production. He is beginning to realize 
that the manufacturer and foundrvman should furnish him 



Roll Over Jolt Moulding Machines for Stnall Moulds 9.7 



with machines that will perform the heavy and drudging part 
of the day's work, without exacting the maximum of his 
effort, and that will yet produce equal or greater results than 
those obtained by the old time methods. 

For producing the smaller size of what has been termed 
"Small Moulds," there has been a demand for a Roll-Over 
Jolt Moulding Machine mounted on wheels, either operating 
on the foundry floor or on Tee rails, placed in the foundry 
floor in such a manner that the machine can be conveyed 
from one end of the floor to the other. The claim is made 
that a greater production can be obtained with less effort on 
the part of the operators, since the distance that the moulds are 
carried from the machines to the floor, is less than when the 
machine is permanently located ; others maintain that the 
machine permanently located has an advantage over the port- 
able machine, claiming that the time and energy consumed 
in moving the machine are equal to that required in carrying 
the moulds the short distance further. This again is largely 
a matter of individual preference, and should be determined 
by the conditions in the foundry in which the machine is to be 
used. Many foundries, using this particular type of machine 
for small work, prefer to set it in a permanent location under 
the chute of a sand-conveying system, which has been found 
to be a highly desirous installation in foundries producing 
castings in large quantities, while others prefer to make use 
of the available sand-cutting machines, in bringing the sand, 
after it has been tempered, from the floor into a pile alongside 
the moulding machine, where it is then readily shoveled into 
the flask before the mould is made. 

The numerous castings and foundry floors shown in this 
chapter will give a good idea of the production obtained and 
will suggest to the reader the great possibilities of machine 
moulding when applied to this class of work. 

The castings produced by this type of machine are true 
to pattern, uniform in weight and, when they are machined 
by the use of jigs, have a decided advantage over the ones 
made by hand ramming. 



9G 



Foundry Moulding Machines and Pattern Equipment 




i.^ 



(U <D 

> J= 

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£ 







Roll Over Jolt Moulding Machines for Small Moulds 



97 




9S 



Foundry Moulding Machines and Pattern Equipment 



Automobile Cylinder Head. 




Weight 38 Pounds. 






Fig. 70 



Production based on making both the cope and the drag half of the mould 
on the same machine. 





PRODUCTION 








Method of Moulding 


No. 
Men 


Hours 


Quan. 

Moulds 


Increase 


Without Machine 


3 


9 


30 




Cope— 20"x27" Plain Jolt. . . 
Drag — 20"x27" Plain Jolt. . . 


......... 3 


9 


60 


100% 






Cope— 22"x37" R. 0. Jolt. . 
Drag— 22"x37" R. 0. Jolt. . 


......... 3 


9 


200 


567% 



Roll Over Jolt Moulding Machines for Small Moulds «« 



Steel Casting Bracket for 6 Ton 
Armored Truck. 



Weight 50 Pounds. 




Fig. 71 



Production based on making both the cope and the drag half of mould on 
the same machine. 



PRODUCTION 



Method of Moulding 


No. 
Men 


Hours 


Quan. 
Moulds 


% 

Increase 


Without Machine 


3 


9 


11 




Cope— 20"x27" Plain Jolt 

Drag— 20"x27" Plain Jolt 


3 


9 


22 
36 


100% 


p<-.T-i«. '">'"> "y"^?" R O Tolt 




9 




Drag— 22"x37" R. 0. Jolt 


3 


227% 



100 



Foundry Moulding Machines and Pattirn Equipment 



Steel Casting Sprocket for 6 Ton 
Armored Truck, 



Weight 125 Pounds. 




Fig. 72 

Production based on making both the cope and the drag half of mould on 
the same machine. 

PRODUCTION 



Method of Moulding 


No. 
Men 


Hours 


Quan. 
Moulds 


Increase 


Without Machine 


3 


9 


10 










Cope— 20"x27" Plain Jolt 

Drag— 20''x27" Plain Jolt 


.... 3 


9 


IS 


80% 


Cope— 22"x37" R. 0. Jolt 

Drag— 22"x37" R. 0. Jolt 


'.'.'.'. 3 


9 


32 


220% 



Roll Over Jolt Moulding Machines for Small Moulds 



101 



Fig. 73 
High Pressure Steam Trap. 



Weight 61 Pounds. 



Production based on making 
both the cope and the drag half 
of mould on the same machine. 




PRODUCTION 



Method of Moulding 



No. 
Men 



Quan. % 

Hours Moulds Increase 



Without Machine. 



18 



Cope— 20"x27" Plain Jolt. 
Drag— 20"x27" Plain Jolt. 



50% 



Cope— 22"x37" R. O. Jolt. 
Drag— 22 "x37" R. O. Jolt . 



133% 



102 



Foundry Moulding Machines and Pattern Equipment 



Timberhead Casting 

Used in the Shipbuilding 

Industry. 




Fig. 74 

Production based on making both the cope and the dra^ half of mould on 

the same machine. 

PRODUCTION 

No. Quan. % 

Method of Moulding Men Hours Moulds Increase 

Without Machine 3 9 21 

Cope— IS "xl 8" Plain Jolt 

Drag— 18"xlS" Plain Jolt :} 9 3(i 71% 

Cope— 22''x37" R. O. Jolt 

Drag— 22".x:57" R. O. Jolt 3 9 4S 131;% 



Roll Over Jolt Moulding Machines for Small Moulds 



103 




Cleat Casting 






r^ 




Used in the Shipbuilding 


( 




y 




Industry. -> 


L 


-h- 




\ ^ 




1 ' 








~T^ 




If 








^Oti^-m. 


3- 
7«-m«i. 






. 1 


/ 


^ 








• 


1 



Fig. 75 



Production based on making botli the cope and the drag half of mould on 
the same machine. 



PRODUCTION 

No. 
Method of Moulding Men 

Without Machine 3 

Cope— 18"xl8" Plain Jolt 

Drag— 18"xl8" Plain Jolt 3 

Cope— 22"x37" R. O. Jolt 

Drag— 22"x37" R. O. Jolt 3 



Qvian. 
Hours Moulds 



36 



60 



100 



% 

Increase 



67% 



180% 



104 



Foundry Moulding Machines and Pattern Equipment 




Roll Over Jolt Moulding Machines for Small Moulds 



105 




o 

a 






1U(J 



Foundry Moulding Machines and Paltern Equipment 




CHAPTER VII 



Jolt Moulding Machines in Brass and 
Aluminum Foundries 

The jolt moulding machine, having had its early devel- 
opment in the iron and steel foundries, was slow to be 
accepted as a machine which would produce the proper type 
of moulds for brass and aluminum castings. Conditions for 

making aluminuni 
castings are greatly 
different from those 
for iron and steel. 
A different grade of 
sand is used, and an 
entirely different den- 
sity of ramming is de- 
sired. For a long 
time it was believed 
that a jolt machine 
could not satisfactori- 
ly ram sucli a movild 
Fig. 79. Liberty Motor Crank Case^ on account of the 

Upper and Lower Half. hardness cf the blow 

which was associated with many early designs of machines. 
The mechanical handling of the equipment is a proposition 
entirely different from the methods employed in grey iron 
foundries. Pouring progresses continuously throughout the 
day, and a comparatively small number of flasks and small 
amount of sand are used over and over during the day ; in 
fact the sand in an aluminum foundry sometimes heats up as 
much as 40 degrees Centigrade during the day, due to its 
being used and re-used. Perhaps it required the stress of war 
conditions with the necessity for a large production with a 
minimum amount of labor, coming simultaneously with the 
problem of the Liberty Engine, to cause the foundry industry 
seriously to try the jolt machine on aluminum castings. 




108 



Foundry Moulding Machines and Pattern Equipment 



When the American engineers designed and began build- 
ing the Liberty Motors in quantities for Government aero- 
planes, it was with a full realization of the possible difficulties 
that would be encountered before all of the many details were 
perfected and the engine pronounced a success, both from 
the viewpoint of reliability of operation and of the practica- 
bility of its adaptation to manufacturing methods. The 400 
H. v., which the motor was to develop, required materials, in 




Fig. 80. Pattern Mounted on Roll Over Jolt Machine. 

fact demanded materials, that would be almost perfect in their 
metallurgical (jualitics and of the highest grade of workmanship. 

Of the many different parts of the engine, the crank- 
case is one that received a considerable amount of attention, 
as failure in this particular part practically meant complete 
destruction of the engine. The inspection, therefore, was care- 
fully made and the materials held strictly to the specifications. 

The aluminum foundries, with the true Yankee spirit, 
began with a determined effort to produce castings that would 



Jolt Moulding Machines in Brass and Aluminum Foundries 



109 




pass inspection and fulfill all 
requirements of the specifi- 
cations. After the casting 
had been successfully pro- 
duced, free from defects, 
the next qiiestion that con- 
fronted the foundry was that 
of production to meet the 
enormous requirements de- 
manded by the Government's 
program. The same deter- 
mination that produced the 
casting successfully from the 
Fig. 81. Jolting the Drag Half metallurgical standpoint, also 
of the Mould. solved the problem of pro- 

ducing the quantities required per day. The Roll Over Jolt 
Mouldin*: Machine was, after due consideration, decided upon 
as being the one best adapted to produce the moulds. 
The views in this chapter were made in the plant of The 
Aluminum Castings Company, Cleveland, Ohio, U. S. A., and 
show the process of moulding and casting the Liberty Motor 
crank cases. An inside and an outside view of the casting 
is shown in Figure 79. These views show clearly the construc- 
tion of the casting, both of 
the top and bottom half. It 
will be noticed that the cast- 
ing has many exceedingly 
thin sections, as well as a 
moderately heavy section at 
the front end. Also that the 
side walls are practically ver- 
tical, making the drawing of 
the pattern a matter demand- 
ing great accuracy. The pat- 
tern mounted on the pattern 
plate and attached to the 
table of the moulding ma- 
chine is shown clearlv in 




Fig. 82. Butting Off the Cope 
Half of the Mould. 



no 



Foundry Moulding Machines and Pattern Equipment 




Fig. 83. Drag Half of Mould Ready for Setting Cores. 




Fig. 84. Drag Half of Mould with Cores Set. 



Jolt Moulding Machines in Brass and Aluminum Foundries 



111 



Fig. 80. It will also be noted in this view that a finished drag 
mould is on the leveling car of the machine. The bottom 
boards used are seen standing against the foundry wall at the 
extreme left. 

In Figure 81 the flask is being filled with sand from the 
bins overhead, which are a part of the sand-conveying system 
with which this plant is equipped. On this size flask two bins 
were used in order to fill the flask more quickly. 

In Figure 82 the jolting operating of the cope half of the 
flask is completed and the workmen are "butting off" the loose 
sand on top of the mould, an operation which can be performed 
in eight to ten seconds of time. 

Too nnich emphasis cannot 
be placed upon the necessity 
of providing the proper flask 
e([uipment when attempting a 
large production. By analyz- 
ing the flask shown in Figure 
8,S. it will be seen that the 
flask \ised is one especially 
adapted to their work. The 
flask is made of aluminum, 
and the trunnion piece has 
been cast separately and pro- 
vided with dove-tailed slots at 
each end ; the purpose of 
these slots is to receive the 




Fig. 85. Making Cores on a Small 
Jolt Machine. 



loose pieces that are used as handles in case it is desired to carry 
the flask without a crane. Bolts are used for securing this trun- 
nion piece to the flask. The pins are located on the side rather 
than on the end, permitting shorter trunnions. This figure also 
shows a splendid detail of the drag half of the mould, after the 
pattern has been withdrawn and the mould set on the foundry 
floor. 

By referring to Figure 84, this same drag half of the mould 
is shown with cores set and ready to receive the cope. There 
are six separate cores used in the body of the mould, practically 



11: 



Foundry Moulding Machines and Pattern Equipment 




Fig. 86. 



tlie same in construction, and 
all made on a small Plain Jolt 
Moulding Machine, as shown 
in Figure 85. These cores 
were produced by first plac- 
ing in the bottom of the core- 
box, a dry-sand slab in which 
has been placed suitable hold- 
ing lugs to which the carrier 
handles are attached. The 
core-box was then filled with 
green sand and jolt-rammed. 
The shape of the core de- 
manded the hinge type of box 
which permitted the swinging 



A View of the Moulding 
Floor. 

of the box from around the core, after which it was carried to 
the green-sand core racks. 

In Figure 86 may be seen a row of moulds, part of which 
are completed and ready for pouring, while others at the far- 
ther end of the row are "shaken out" and ready for cleaning. 
The small core referred to above is here seen with the lifting 
handles in place, standing beside the drag half of the mould 
appearing in the foreground. 

Figure 87 shows a close up 
view of the distant end of 
the row of moulds in the 
preceding view. The sand 
has been shaken from the 
moulds, and the castings ap- 
pear as thev are before being 
sent to the chipping and 
cleaning rooms. The remark- 
able production obtained by 
the use of moulding machines 
on this casting is exceptional, 
as eight men produced 102 

moulds per day, the cope and j... „, r^. ^ ... ^, 

^ • ^ Fig. 86. The Castings as thev 

drag being made on different Appear When Shaken Out. ' 




Jolt Moulding Machines in Brass and Aluminum Foundiies 113 

machines. The best resuhs obtained under former condi- 
tions was the production by eight men of 16 moulds per 
day. It should be noted also that the production from the 
hand ramming method resulted in a scrap loss of 30%, while 
the scrap loss from the moulds made on the Roll Over Jolt 
Moulding Machine was less than 10%. 

The success of the Roll Over Jolt Machine in making the 
Liberty motor crank case castings has called the attention of the 
progressive brass and aluminum foundrymen to the use of the 
machine, and in the comparatively short time that has elapsed, 
machines have been installed in a large number of shops. 

No radical departures are made from the practice followed 
in iron foundries. The finer sand used is more fluid and 
demands less packing force to produce a given density than the 
coarser sand used in iron work ; also, a much lower density 
is used for aluminum work, since the liquid pressure exerted 
by an aluminum casting is only one-third that which would be 
exerted by an iron casting from the same pattern, and the 
density of the sand should be proportional to this pressure. 
The adjustable valve for controlling the jolt stroke is set for a 
very light blow and from four to ten jolts is considered good 
practice. 

One by one the superstitions in regard to the jolt machine 
are being dispelled. Some foundrymen hesitated for a long 
time before attempting copes on a jolt machine, but no one has 
doubt on this subject any longer. Others hesitated on account 
of the damage, from the shock of the machine, to moulds 
already on the floor, but this is a subject which has also dropped 
from popular interest. The belief that the machine was not 
suitable for aluminum work has now been successfully pushed 
into the background, and this type of machine is well on its 
way toward filling the universal field which it is destined to 
occupy. 



114 



Foundry Moulding Machines and Pattern Equipment 



I ' 





Fig. 88. 



A Large Plain Jolt Moulding Machine with the Foundation 
Shown in Phantom. 



CHAPTER VIII 
Plain Jolt Moulding Machines 

Development 

In the early development of the jolt ramming method of 
moulding, the Plain Jolt Machine was built essentially in the 
same form as we know it today. These early experiments 
extended over a period of about fifteen years, and resulted in 
the development of a machine which had proven satisfactory 
for the production of large varieties of castings. 

Reference has been made to the tendency in the foundry 
to consider that the use of moulding machines must be accom- 
panied by a complete change in the type of patterns used. This 
mistaken belief has caused many foundrymen to think that they 
did not possess the necessary knowledge required to re-equip 
their patterns for machine moulding. 

The facts are that any pattern whicli has been made for 
floor moulding can be used on the Plain Jolt Machine and also 
on the Roll Over Jolt Machine. The knowledge necessary for 
the use of patterns on machines is not complicated and can 
easily be acquired by any foundry man. Many foundrymen, how- 
ever, u:?e Plain Jolt Machines when they should be using Roll 
Over Jolt IMachines, and many others are producing moulds 
on the floor when they should be using machines. Under the 
economic stress which exists and which will continue to exist, 
the adoption of labor-saving devices will be in some measure 
forced upon those who. at present, are not making full use of 
them. 

Production 

The Plain Jolt Moulding Machine performs only the one 
operation, viz., jolt ramming; replacing hand ramming. It is 
evident, therefore, that the ultimate time saving which may be 
accomplished by this machine is the saving of the time expended 
in this one operation. Studies show, that in floor moulding 
the average time required for ramming is approximately 50% 
of the total time required for making the mold. 



116 



Foundry Moulding Machines and Pattern Equipment 



This time is reduced to a very small amount by the Jolting 
Machine, which jolt rams the mould in 5 to 10 seconds, leaving 
only the butt ramming operation which does not require careful 
and expert work, and which can be performed in from 15 
seconds to 5 minutes, depending upon the size of the mould. 
The time of rolling over is not aflfected, nor is the amount of 
time required to draw the pattern. 




Fig. 89. A Plain Jolt Machine of Rigid Construction. 



Quality of Castings Produced 

The influence of jolt ramming on the quality of the cast- 
ings is as marked as is its influence on the amount of produc- 
tion. Ninety-five per cent of all defective castings may be 
traced to two causes: 1st — unequal ramming; 2nd — slicking 
and patching due to a faulty pattern draw. Most of those 
troubles arising out of improper ramming are eliminated on jolt 
rammed moulds, as the sand is packed practically uniformly and 



Plain Jolt Moulding Machines 117 

evenly over the surface of the pattern and pattern plate. After 
the mould is jolt rammed, however, there remains the hutting 
off operation to be performed by hand. 

This prevents the ramming operation from being quite as 
fast as it otherwise would be, and also introduces a slight 
human variation in the density of the rammed sand. The 
limitations of the usefulness of the Plain Jolt Machine should 
be mentioned here. 1 lie ideal iiioitldiiu/ macliinc is one Schick 
mccJianically pcrforjiis all of flic operations of making a mould 
with a uiiiiiinitin ainoiint of time and effort and with a ina.vi- 
mnm of accuracy and exact repetition. The Plain Jolt Ma- 
chine fc'.lls short of this ideal in that there remains to be done 
by hand — 

1. Butting off. 

2. Rolling Over. 

3. Drawing the pattern. 

Design and Construction 

As we know it today, the Plain Jolt Moulding Machine 
is simple and rugged in construction. Simplicity of construc- 
tion does not mean, however, that there are no problems affect- 
ing the design of the machine or the construction of it. Sub- 
jected as it is to the hardest use with a minimum of attention, 
the Plain Jolt Machine is expected to have a long life of useful 
service, maintaining its accuracy throughout its life. 

One of the principal factors affecting the accuracy of the 
machine is the relation of the piston diameter to piston length. 
If the piston is too short in relation to its diameter, it will tend 
to lean in the cylinder toward the side which is more heavily 
loaded, and will thus cause a slapping action of the table when 
it strikes, particularly if the impact surface is of a large area 
and is located around the cylinder at the top. Adequate length 
of piston is necessary, as increasing the length of the piston 
decreases the angle at which the table might lean from the 
horizontal. 

In years past much has been said regarding the merits of 
the bottom or center strike type of machine, as compared with 



118 



Foundry Moulding Machines and Pattern Equipment 



the top strike machine, in which a large area of the table con- 
tacts with the base of the machine. Much can be said regard- 
ing the merits of the two ditlferent types ; nevertheless, there 
is today no controversy, as both are producing moulds satis- 
factorily. 

The working action of the Jolt Moulding Machine is such 
as to cause a vibration throughout its different parts. This 
vibration, of course, becomes exaggerated when the machine is 




Fig. 90. The Machine Shown Here is Mounted with the Top of the 
Table Level with the Floor. 



made up of many different castings. It has been found exceed- 
ingly difficult to bolt together the different parts of a machine 
in a manner that will withstand the severe vibration produced 
in the bolted members. Where bolts are used, it has been 
found that the best type of lock washers are not sufficiently 
strong ond rigid to hold the parts in place, and, therefore, if 
bolts arc a necessity, a method should be employed that will 



Plain Jolt Moulding Machines 



119 



absolutely prevent the loosening of the bolt; for if only a few- 
bolts loosen, and the remaining bolts hold tight, an exceptional 
strain is produced on those that are holding, thereby causing a 
breakage of the casting or of the bolts. Modern tendency is 
toward a machine designed with as few parts as possible, elim- 
inating the bolted construction, and using in its place a design 
that will withstand the severe vibration caused by the jolting 
action. 




Fig. 91. A Small Plain Jolt Machine of Simple Construction. 

Since the action of the Jolt jVIachine in operation is severe 
and very much like the action that is used in breaking up scrap 
iron for the cupola, it is obvious that a machine that will with- 
stand the repeated blows of jolt-ramming should be of a mas- 
sive an'l heavy construction, preventing as much of the blow 
as possible from reaching the different parts. 

In order to produce an economical operation by the con- 
sumption of the smallest amount of air, it is well to examine 
critically the many different syles of valves on Plain Jolt Mould- 
ino- Machines. It is essential, in order to conserve the com- 



120 Foundry Moulding Machines and Pattern Equipn ent 

pressed air, that there be some means of controlling the amount 
used, and also to shut off the inlet port of the machine during 
the exhaust stroke. If the air inlet is permitted to remain 
open during the exhaust stroke, a large amount of air is use- 
lessly consumed by its blowing thru the machine and into the 
exhaust. 

While the jolt ramming of a mould is a comparatively 
simple operation, yet considerable difficulty has been encountered 
in years past, in the ramming of the moulds required in found- 
ries producing castings from various metals. The stroke 
required, on Jolt Moulding Machines, that will economically 
and properly pack the sand of a steel casting mould, varies 
considerably from the stroke that is required to produce the 
mould into which is to be poured iron, brass or aluminum. In 
addition to the varying degree of hardness required in the 
mould, there are the factors introduced by the use of the differ- 
ent grades of sand that are required in making the mould. 
To meet these varying conditions, it is well to have a machine, 
the stroke of w^hich can be adjusted to suit the requirements. 
The stroke, however, when once set for a particular foundry, 
rarely, if ever, requires further adjustment. The adjustable 
featue of the stroke, which, of course, is obtained by adjusting 
the valve on the machine, is, many times, a decided advantage 
when difficult copes are to be made, which in many instances 
require a long stroke with a sharp, quick blow, while in the 
majority of moulds a shorter stroke, with lesser blow, will 
accomplish the results in the same time and without the same 
amount of detrimental action to the machine and pattern equip- 
ment. 

In the early years of moulding machine operation, there 
existed in the minds of foundrymen the feeling that the ma- 
chine, when once installed in the foundry, should operate and 
give entire satisfaction without being cared for by a competent 
mechanic. They did not realize the importance of keeping the 
machine properly oiled and free from sand obstruction. There 



Flain Jolt Moulding Machines 121 



should be in every foundry operating moulding machines, a 
mechanic with sufficient mechanical knowledge to inspect the 
machine properly and to keep it in good working condition. 

The pattern and flask equipment is another important item 
that has not been given the proper amount of consideration. 
Experience has thoroughly demonstrated that in order to se- 
cure the best results, proper attention must be given to equip- 
ping the machine with patterns, flasks, bottom boards and oth- 
er necessary auxiliaries. In equipping the machine with pat- 
terns, care should be exercised to secure the pattern plate 
firmly, and patterns having a large flat surface should be thor- 
oughly and strongly supported from the bottom, in order to 
remove the possibility of a springing action taking place in the 
pattern when the mould is being rammed. If the pattern is 
not properly supported and a springing action takes place, the 
mould produced will be full of cracks, and if a cope, will be 
likely to drop out when the flask is being handled. 

The flasks should also be examined to see that they are 
rigid and of sufficient strength to prevent a springing action. 
The best results have been produced by the flasks that are 
cast solid in one piece in the small sizes and are of securely 
bolted construction in the larger sizes. This is especially im- 
portant when designing the cope half of the flask, and yet in 
some instances it is difficult to cast integral the flask and the 
proper bars for supporting the sand. If it is found neces- 
sary to make use of separate bars, they should be secured to 
the flask by means of tightly fitted bolts, as a loose bar will 
prevent the making of a satisfactorily rammed mould. The 
above description of the equipment necessary in jolt ramming 
applies not only to this particular chapter, but to all machines 
which make use of the jolt ramming principle. 

The following pages illlustrate the increased production 
obtained by the use of the Plain Jolt Moulding Machine on a 
variety of different kinds of moulds. The increase of produc- 
tion in each case is given and it will be noticed that this in- 
crease averages about 100 per cent. 



122 



Foundry Moulding Machines and Pattern Equipment 




Fig. 92. Generator End Frame made on a 54"x66" Plain 
Jolt-Moulding Machine. 



The cope and the drag half of the mould ara both made on this machine. 



Plain Jolt Moulding Machines 



123 




Fig. 93. A Floor of Generator End Frame Moulds Made on the Plain 
Jolt Machine Shown in the Foreground, at the Plant of 

THE WESTINGHOUSE ELECTRIC & MFG. CO. 
Cleveland, Ohio, U. S. A. 



124 



Foundry Moulding Machines and Pattern Equipment 



Generator End Frame Casting. 



Weight 210 Pounds. 




Fig. 94 

Production based on making both the cope and the drag half of the mould 
on the same machine. 

PRODUCTION 

No. Quan. % 

Method of Moulding Men Hours Moulds Increase 

Without Machine 2 9 6 

Cope— 54"x66" Plain Jolt 

Drag— 54"x66" Plain Jolt 2 9 12 100% 

A Roll-Over Jolt-Moulding Machine would give an increase in production of from 400 to 500%. 



Plain Jolt Moulding Machines 



125 



m 1.143 



y$^^^^y^x^;;ms;^ii^i^^s>!^■y^^ 






Fig. 95 
Steel Casting Press Cylinder. Weight 610 Pounds. 

Production based on making both the cope and the drag half of the mould 
on the same machine. 

PRODUCTION 

No. Quan. % 

Method of Moulding Men Hours Moulds Increase 

Without Machine 4 9 2 

Cope— 54"x66" Plain Jolt 

Drag— 54 "x66" Plain Jolt 495 \5Q% 

A Roll-Over Jolt-Moulding Machine would give an increase in production of from 300 to 400%. 



126 



Foundry Moulding Machines and Pattern Equipment 





Fig. 96 
Railway Truck Bolster— Steel Casting. Weight 430 Pounds. 



Production based on making both the cope and the drag half of the mould 
on the same machine. 



PRODUCTION 

No. 
Men 

5 

'.'.'.'.'..'.'. 5 

A Roll-Over Jolt-Moulding Machine would Rive an increase in production of from 300 to 400% 



Method of Moulding 


No. 
Men 


Hours 


Quan. 
Moulds 


T ^^ 

Increase 




5 


9 


12 










Cope— 42"x97" Plain Jolt 

Drag— 42"x97" Plain Jolt 


'.'.'.'. 5 


9 


30 


150% 



Plain Jolt Moulding Machines 



127 



^ 



7a 

m'lSai 



vrnM^/^^MmMm/'m/m/ ' /' 



i 




Standard 

Open Hearth 

Ca^t Steel Char^in^ Box 



TheWcllman-Sedver-Morrf^an Co., Clcvcland.Ohio 

Fig. 97 
Weight of Casting 1210 Pounds. 



Production based on making both the cope and the drag half of the mould 
on the same machine. 

PRODUCTION 

No. Quan. % 

Method of Moulding Men Hours Moulds Increase 

Without Mat;hine 4 9 2 

Cope— 54"x66" Plain Jolt 

Drag— 54 "x66" Plain Jolt 4 9 6 200% 

A Roil-Over Jolt-Moulding Machine would give an increase in production of from 300 to 400%. 



12S 



Foundry Moulding Machines and Pattern Equipment 



Base and Cylinder Cast 
Integral. 




Weight 1700 Pounds. 




Fi-'^-^ 



Fig. 98 



Production based on making both the cope and the drag half of the mould 
on the same machine. 



PRODUCTION 



Method of Moulding 


No. 
Men 


Hours 


Quan. 

Moulds 


% 
Increase 


Without Machine 


4 


9 




2 










Cope — .54"x66" Plain lolt 




9 




4 




Drag— .'i4"x6(i" Plain Jolt 


4 


lOO^c 



A Roll-Over Jolt-Moulding Machine would give an increase in production of from 500 to 600%. 



Plain Jolt Moulding Machines 



129 





^/8" 



Fig. 99. Side Frame Casting. 



Weight 800 Pounds. 



Production based on making both the cope and the drag half of the mould 
on the same machine. 



PRODUCTION 

No. Quan. % 

Method of Moulding Men Hours Moulds Increase 

Without Machine 4 9 2 

Cope — 54"x66" Plain Jolt 

Drag— 54"x66" Plain Jolt 4 9 4 100% 

A Roll-Over Jolt-Moulding Machine would give an increase in production of from 400 to 500%. 



130 



Foundry Moulding Machines and PatUrn Equipment 




Fig. 100 

Truck Center Casting for Locomotive Crane. 
Weight of Casting 1680 Pounds. 



Production based on making both the cope and the drag half of the mould 
on the same machine. 

PRODUCTION 

No. Quan. % 

Method of Moulding Men Hours Moulds Increase 

Without Machine 3 9 1 

Cope — 54"x66" Plain Jolt 

Drag— 54 "x66" Plain Jolt 3 9 2 100% 

A Roll-Over Jolt-Moulding Machine would give an increase in production of from 400 to 500%. 



Plain Jolt Moulding Machines 



131 




Fig. 101. Large and Difficult Table Casting. Weight 1500 Pounds. 



Production based on making both the cope and the drag half of the mould 
on the same machine. 



PRODUCTION 



Method of Moulding 



No. 
Men 



Quan. % 

Hours Moulds Increase 



Without Machine. 



Cope— 54"x66'' Plain Jolt . 
Drae— 54"x66" Plain Jolt. 



100% 



A Roll-Over Jolt-Moulding Machine would give an increasejn production of from 500 to 600%. 



132 



Foundry Moulding Machines and Pattern Equipment 




CHAPTER IX 
Air Operated Squeezer Moulding Machines 

Primarily, the air operated squeezer type of moulding ma- 
chine was designed to replace the old laborious hand method 
of bench moulding of light work. The question of producing, 
rapidly and economically, large numbers of small castings from 
one pattern, is one that cannot be lightly viewed as a subject 
of little importance ; this fact is evident from the varied and 
interesting devices designed to facilitate the squeezer class of 
foundry work. The first development in the art of squeezer 
moulding produced a single pattern with its match of green 
sand; next, a single gate; then the improving of the green 
sand match by the substitution of fireclay or oil sand for the 
delicate green sand ; further development produced a match 
board similar to the modern match plate. The various plates 
were first used for hand ramming on the bench, but soon a 
squeezer machine came into favor, and was extensively use<l 
throughout the United States of America. 

The original type of air operated squeezer was designed for 
one purpose, that of squeezing the mould, as its name implies, 
and this type, subject to its limitations, is still doing efficient 
and rapid work. With the plain squeezer type of machine, 
the most common and most extensively used form of pattern 
is the match plate type, although the vibrator frame and hard- 
sand match are also frequentl}- used. 

Combination Jolt Squeezer 

Later it was found that a great many patterns belonged in 
the squeezer class of work, as the weight of the casting was 
such as could be produced by squeezer moulding, but the 
depth of the patterns seemed to prevent their use, as the 
squeezing failed to pack the sand properly at the bottom of 
the pattern and firmly against the match plate ; to meet this 
difficulty a machine was designed that embodies the principles 
of both the squeezer and the jolt machines. This machine is 
in appearance the same as a standard air operated squeezer, 



Vi4 



Foundry Moulding Machines and Pctlern Equi-pment 



but is in reality a Jolt Squeezer Moulding Machine. It has, 
nK)unte(! within the large squeeze piston, a small jok cylinder. 
in which operates the jolt piston carrying the table of the ma- 
chine, usually cast integral with the piston. Xo changes are 
required to use either feature of this dual machine, hence a 
deep mould may be jolted to pack a deep recess, by a slight 
pressure of the knee against an air inlet valve. A few jolts 
of the mould settles and begins the packing of the sand in the 
recess of the pattern and the corners of the tiask. after which 
the mould is squeezed in the usual manner. ])acking the remain- 
der of the sand in the flask. This featm-e of double utility 




Fig. 10.^. An Air Operated Squeezer Moulding Machine with the 
Mould in Position for Squeezing. 

is also an effective means of preventing what is known as a 
"ram-ofif". an annoyance caused 1)\- the sand, after being tucked 
against the side of the pattern or into a depression, being 
pushed r.way again by the squeezing action of the Plain Squeez- 
er Machine. These machines are used not only in the Stand- 
ard design, but also with other special attachments, for exam- 
l)le, a stripping or pattern drawing device, and when so equip- 
ped is commonly known as a Split Pattern Machine. These 
machines are used for a heavier class of work, such as fly- 
wheels for small gas engines, valve and pipe fittings, gears, and 
for such patterns as require stooling. They are usually operated 



Air Operated Squeezer Moulding Mr. chines 



135 



in pairs ; the drag pattern mounted on one machine and the 
cope pattern on the other. llie addition of this device does 
not in any way interfere witli the usual operation of the ma- 
chine as a standard squeezer. 




-^ 



Fig. 104. A Split Pattern Machine 

Operation of the Jolt Squeezer Machine 

In detail the operation of the Jolt Squeezer type of mould- 
ing machine is as follows : The cope flask is placed up side 
down on the table of the machine ; the pattern plate is placed 
on top of the flask with the drag side up and the drag half 



130 Foundry Moulding Machines and Pattern Equipment 

of the flask placed in position. The pins which are fastened 
in the drag half of the flask will align, and hold in alignment, 
the three parts just mentioned. The drag half of the flask is 
now filled with sand in the usual manner, and a conveniently- 
operated knee valve allows the operator to jolt the mould at 
the same time that he reaches for the bottom board. The jolt- 
ing is performed very quickly, it having been found from 
experience that from 5 to 20 blows are generally sufficient. As 
soon as the jolt operation is completed, the operator places the 
bottom board on the mould, and proceeds to roll the complete 




Fig. 105. An Air Operated Squeezer Moulding Machine with the 
Pattern Drawn from the Mould. 

flask over, utilizing the forward edge of the table to hold the 
bottom board in position during the operation. The cope half 
of the flask is now filled with sand and the squeezer head pulled 
forward into position, and the valve handle controlling the 
squeezing operation pushed down, causing the table to rise and 
to squeeze the mould against the pressure head. Both halves 
of the mould ru-e squeezed at one operation, but only the drag 
half of the mould has been previously jolt rannned. In squeez- 
ing the mould, a pop valve is used which automatically releases 
ihe pressure when it reaches a certain ])redetermined value; 
tbe squeezer licad is pushed Ixuk. the scjueezer board removed, 
and. after cutting the sprue, the cope half of the mould i= 



Air Operated Squeezer Moulding Machines 137 



drawn upward from the pattern plate, guided by the pins at 
either end, and loosened by the vibrator which is placed in 
operation by a conveniently located knee valve. After setting 
the cope on a table provided at the left, the operator draws 
the pattern from the drag half of the mould, utilizing the vibra- 
tor to prevent sticking. 

There is now a completed drag half of the mould sitting 
on the bottom board on the table of the machine, and a cope 
half of the mould on the table at the left, and all that is neces- 
sary is to close the two, remove the flask and set the mould 
in its place for pouring, on the floor. For a graphical explana- 
tion of this process the reader is referred to i)agc 14 oi Chapter 
I, where the different steps are illustrated by sketches accom- 
panied by explanatory notes. 

The method of making a mould on the Split Pattern 
Machine is very similar, except that only one half of the mould 
is made at one time, and the unnecessary steps are omitted. 
The Split Pattern Machine frequently substitutes a mechanical 
lifting device for drawing the mould from the pattern, operated 
either by hand or by air. 

Operation of the Plain Squeezer Machine 

The Plain Squeezer Machine, without the jolt operation, has 
the following sequence of operations in making a mould. The 
cope half of the flask, pattern, and the drag half of the flask 
are placed on the table in the order named; the drag half of the 
flask is hlled with sand, the corners and edges tucked by hand; 
the bottom board is placed on the mould and the mould rolled 
over without squeezing; the cope half of the flask is then filled 
with sand, the squeezer board placed on top and both halves 
of the mould are squeezed simultaneously. The remaining oper- 
ations are identical with those of the jolt squeezer machine. 

It can readily be seen that on the plain squeezer machine, 
the pressure developed on opposite sides of the pattern plate is 
equal, and a comparatively thin plate will be satisfactory, espe- 
cially since this pressure is applied slowly. On the Jolt Squeezer 



i:}S 



Foundry Moulding Machines and Pattern Equipment 



Machine, however, the drag half of the mould is jolted before 
the cope is filled with sand, and the pattern plate should have 
sufficient strength to withstand the forces exerted on it. 

In comparing the Plain Squeezer and the Jolt Squeezer 
types of machines, it is well to bear in mind the following facts: 
The Jolt Squeezer Machine eliminates the hand tucking which 
is necessary to supplement squeezing on deep moulds, but it 
requires a much more substantial pattern plate. Due to the 
elimination of hand labor, the Jolt Squeezer Machine will turn 
out a r,lightly larger quantity of moulds per day, and in this 
way will pay for the increased investment. Another factor, 
^vhich is too fre(iuently overlooked, is that by eliminating some 




Fig. 106. An Air Operated Jolt Squeezer Movilding Machine 
Showing a Deep Drag which was Jolted. 

of the manual labor, the foundry worker's task is made a more 
desirable one, and his attitude toward the foundry is much 
better. 

The standard types of Air Operated Squeezer Moulding 
Machines are usually mounted on wheels. The advantage in the 
use of this construction is that, if desired, the machine can be 
moved along the side of the sand heap on the working floor, or 
it can be permanently located, and the sand piled in a heap 
beside it. 



^4ir Operated Squeezer Moulding Mcchincs 139 

Another style of air operated squeezer is that known as the 
Sand Straddler, which is mounted on wheels having a wide 
span. This machine is designed to straddle or span the sand 
heap, the sand being piled in long rows, but shorter than the 
length of the moulding floor, to permit placing the first moulds 
and to allow working space. As the floor is filled with moulds, 
the machine is pushed ahead, the sand being taken from beneath 
the machine. 

Design 

In air operated squeezer machines of any size or type, 
should be found incorporated the following principles : All 
working parts should be fully enclosed or shielded against sand 
and grit ; the place for moulding sand is either in the mould 
or on the floor, hence the contours of the exposed members of 
the machine, as far as possible, should be of the inverted "V" 
design so as to shed the falling sand ; simplicity of operation 
is essential to its proper working under the conditions usually 
existing in the foundries ; pistons should be provided with cast 
iron piston rings and proper oiling facilities; the strain rods 
carrying the pressure head should be adjustable for height, to 
meet the conditions existing due to varying height of flask 
used ; tiie pressure head and strain rods should be counter- 
balanced ; the operating valve should be in a convenient location 
at the right of the operator and below the working position of 
the table ; this operating valve should be automatically locked 
except when the pressure head is in the squeezing position ; 
there should be a release pop valve, releasing the pressure in 
the cylinder when the mould has been squeezed to a predeter- 
mined densit}', there should also be a pressure gauge, a blow 
valve, a riddle bracket, and a shelf for holding the cope half 
of the mould while drawing the pattern from the drag half 
which is still left on the table of the machine. These features 
make of the machine a self-contained and independent unit. 

Production 

The- following photographs. Figures 107 and 108 show the 
production of the squeezer machines. It is easy to see that 



140 



Foundry Moulding Machines and Pattern Equipment 




Air Operated Squeezer Moulding Machines 141 



they produce moulds in large quantities, but such vague gener- 
alities are not acceptable to practical foundrymen. Production 
ranges from 50 to 250 moulds in a working day, depending 
upon the following conditions : 

1. The size of the flask. 

2. The number of cores to be set. 

3. The difficulty of pattern draw. 

4. The mounting of the pattern. 

Considering these factors in detail: The first of these is 
the size of the flask. It is readily seen that a larger flask, being 
heavier, will fatigue the operator more than a smaller flask, 
since he must handle each flask several times during the opera- 
tion of making each mould — first, when he places it on the table 
with the pattern in between the two halves; second, when he 
rolls it over with the drag half full of sand; third, when he lifts 
the cope half from the pattern plate; fourth, when he places 
the cope half back onto the drag half; fifth, when he removes 
the flask from the mould; sixth, when he places the finished 
mould on the floor. In all of the above cases, the greater 
weight of the larger size is the principal factor, except in the 
sixth case, namely setting out the finished mould on the floor; 
here another factor enters into the element of difficulty of han- 
dling: This is the shape of the flask or the relation of the 
width to the length. A mould 14" x 14" will be more difficult 
to handle and will be more tiring to the operator than a mould 
10" X 20", although the 10" x 20" mould is the heavier of the 
two. This is because the long narrow mould may be held 
closer to the body, whereas the square mould must be held 
further from the body, making it very much more difficult to 
handle and much more tiring. 

The second consideration, the number of cores to be set, is, 
of course, self-evident. The more cores there are to be set, the 
more will be the time required, and the smaller the number of 
moulds that can be expected from one man. 

The third, the difficulty of pattern draw, affects the speed 
with which the cope can be drawn up from the match plate, or 
the match plate from the drag mould, or both, and in this way 



1-12 



Foundry Moulding Machines and Pattern Equipment 




Air Operated Squeezer Moulding Machines 143 



a pattern with a difficult draw will decrease the number of 
moulds which can be produced per day. 

The fourth, the mounting of the pattern, is most important 
and deserves more attention than the others. 

Pattern Mounting 

The method of mounting the pattern should be given exten- 
sive study, as it is here that the greatest advantages in produc- 
tion are possible. The rule in seeking for quantity production 
is to make the pattern so that the patternmaker lias eliminated 
as mitcl: of the moulders' icork as possible. The rca-^on tor this 
rule is almost obvious. Any operation which can be eliminated 
in the foundry will be that much time saved over and over 
again as many times per day as there as moulds made, and 
this saving of time, large in the aggregate, will more thrm off'set 
what might seem at lirst to be a large ex})enditure of time in 
the pattern shop. 

X'iewing the construction of the pattern in this light we 
have the one extreme, the simple, loose pattern which is some- 
times used in an emergency, but which requires a skillful 
moulder to bed the pattern into a green sand match, and to cut 
the parting by hand. Since this is only an emergency method 
of producing moulds the first method to be considered is the 
use of ilie gated pattern with a follow board or match. This 
follow i>oard may be either of wood or of hard sand, and 
enables the moulder to lay the pattern on the follow board, 
which takes up the irregularities in the shape of the pattern, to 
ram up ihe drag half direct and then, after making the parting, 
to ram up the cope half. The gates are introduced in the 
mould without the necessity of the moulder cutting them each 
time. The next step forward in pattern equipment is the 
vibrator frame, Avhich allows the use of a vibrator instead of 
hand rapping. 

The match plate is the next forward step in producing 
moulds on the squeezer machine. It eliminates entirely the 
handling of a follow board and eliminates the making of a 
parting and the ramming of green sand against green sand. 



Foundry Moulding Machxnes and Pattern Equipment 




rl'' ;^1^ 



>Xi 



** ^-.^'i^ 




-J-'J""mf\^**^'^ 



■iHl*.J^V\ 



V t * • 







Air Operated Squeezer Moulding Machines 145 

allowing both halves of the mould to be rammed directly against 
a metal plate. Chapter XI, on patterns will explain more fully 
the differences in the construction of the various kinds of pat- 
terns. Their use is as follows: 

The Use of Match Plates and Vibrator Frames 

The use of a match plate on an Air Operated Squeezer 
Machine requires in addition to the match plate, a flask parting 
compound, a tubular sprue cutter, a quantity of bottom boards, 
a cope board and the vibrator. The cope half of the flask 
is placed on the table of the machine, and upon this the match 
plate — the cope side being turned downward. The parting sub- 
stance is then dusted over the drag side of the match plate, and 
sufficient sand riddled into the flask to completely cover the pat- 
tern. Sand is then taken from the sand heap to fill the flask, 
and the flask is "struck off," using the bottom board for a 
"strike,"' and the bottom board is placed in position on the 
mould. The bottom board must be about ^" smaller all around 
than the inside of the flask. The mould is now rolled over, and 
the operation is repeated to fill the cope flask. Instead of a 
bottom l>oard, however, a cope board is used, which is similar 
to the bottom board, but has a button secured to the face of it, 
serving to locate the position of the sprue. The pressure head 
is then drawn forward, the operating valve handle pressed 
down and held until the relief or "pop" valve operates. The 
squeezing is then complete. The pressure head is next pushed 
back, and the cope board removed. The .sprue is cut by means 
of a brass tube sprue cutter, at the point indicated by the 
impression of the button secured to the cope board. The vibra- 
tor is then started by pressure of the knee on an air inlet valve, 
and the cope half is drawn off and set on the shelf at the left 
side of the machine. The vibrator is again applied, and the 
match plate of patterns is withdrawn from the drag half of the 
mould; the match plate is then placed on the pressure head. 

The vibrator frame type of pattern is moulded in a similar 
manner. The pattern, in its hard match, is placed on the table 
of the machine, the drag flask set in place, and the sand riddled 



14C. 



Foundry Moulding Machines and Pattern Equipment 




Jir Operated Squeezer Moulding Mrchines 147 

into the flask, which is then filled and struck off. The bottom 
board is then placed, and the mould is rolled over. The match 
is then removed and replaced by the cope flask. The pattern 
and the sand in the drag flask are dusted with parting com- 
])nund, c'md the cope is tilled with sand, in the same manner as 
the drag. The cope board is placed on the top, the pressure 
head drawn into position, and the squeezing o])cration performed 
as befo-2 described. The cope board is tiien removed and the 
sprue cut. The pattern is vibrated while the cope half is drawn 
ui)ward and is vibrated again as it is drawn from the drag. 
The impressions of the strips holding the pattern in the frame 
must be stopped off with sand, after which the mould is closed 
and placed on the pouring floor. 'J'he ordinarv gated pattern 
is handled in the same manner as the vibrator frame, except as 
there is no means of attaching a vibrator to the pattern, it is 
rapped thru the sprue, as in ordinary bench moulding, and a 
draw spike is used for lifting the pattern from the drag half 
of the mould. . 



148 Foundry Moulding Machines and Pattern Equipment 




Fig. 111. A Jolt Stripper Moulding Machine. 




Fig. 112. A Jolt Squeeze Stripper Moulding Machine. 



CHAPTER X 



Jolt Stripper Moulding Machines 

Tlvj iiiacliines classihcd under this lieading arc those 
which joh rain the mould, and then strip the i)attern from 
llic mould, and those which jolt ram, sciucezc and then strip 
the mould. In both cases the strii)])ini^ oi)eration may mean 
either liftiui,^ the mould upward from a stationary pattern 
or dropping the pattern downward from a stationary mould. 
Figure 113 shows a stationary tyi)e of machine used on small 
work which embodies the lirst mentioned principle, that of 
lifting the mould upward from the pattern. This type of 
machine is further illustrated in iMgure 114. which shows the 
stripping plate in the raised position and the mould lifted 
from the plate and turned up for inspection. The last men- 
tioned tvpe of machine, viz.. the one that draws the pattern 
downward from the stationary mould, is illustrated in Figure 
115, which shows a small .stationary hand operated machine. 
It is readily seen that the roll over operation is not incorporated 
in anv of these machines and that its normal use. therefore, is 
for making the cope halves of the mould, although the drag 
halves are frequently produced on these machines. In such 
cases the drag half of tlu 
flask is barred like a cope 
half. The Jolt Stripper Ma- 
chine is frequently used in 
connection with Roll Over 
Machines, the one making 
the cope half of the mould, 
and the other the drag half 
In such cases the Jolt Strip- 
per Machine is alv.ays more 
rapid in operation than the 
Roll Over Machine and in 
some instances it has been 
found possible for one Strin pj^. ^j, a Small Jot Stripper 

per machine to sutiply th.e Machine in the Foundry. 




150 



Foundry Moulding Matliinrs and Pattern Eqmpment 




Fig. 114. A Jolt Stripper Machine 
with tlie Table Raised. 



cope halves of the moulds for 
the total number of dra^ 
halv^es made on two Roll 
Over Machines. The choice 
of the Jolt Stripper Machine 
for producing cope moulds is 
usually made as a result of 
one of two factors ; first, the 
pattern is of such intricate 
sliape with such thin projec- 
tions of sand, that the ordi- 
nary jiattern drawmg opera- 
tion would damage the mould. 
In such cases a stripping 
plate is necessary for the 
making of good moulds. In 
the second case the Jolt Stripper Machine is used with patterns 
which could also be used to produce moulds easily by any other 
method, but on account of the large quantity production the 
advantages of the greater speed of the Jolt Stripper Machine 
more than offset the increased cost of pattern mounting. 

The mounting of the strip- 
ping plate, pattern plate and 
pattern with regards to each 
other varies in the practice 
of different foundries. Figure 
116, page 151, illustrates the 
two most common methods. 
The bottom view show^s a 
method suitable for use with 
patterns which have already 
been made, and which can be 
mounted directlv on. the spe- 
cial pattern plate, but this Fia- 115. A Hand-operated Machine 

^ ^ Which Strips the Pattern 

special pattern plaie must be Downward. 




Jolt Stripper Moulding Machines 



151 



of the shape of the pattern, so that the total amount of work 
to be done on the pattern equipment is about the same in each 
case. The location of the pins is also decided differently by dif- 
ferent toundrymen and Figure 116 shows two of the common 
methods in use. In the top view, the pins are attached to the 
stripping plate, and the finished moulds after they have been 
stripped, must be lifted off the pins ; while, in the bottom 
view the pins are attached to the pattern plate, and when the 
stripping operation is completed, the finished mould can be lifted 
off of the stripping plate without the trouble of disengaging it 
from the pins. This method is referred to by foundrymen as 
stripping the pins, and is preferable whenever conditions warrant. 

The gate is frequently mount- 
ed on the upper side of the 
stripping plate and when this 
is the case the mould must be 
lifted vertically from the 
stripping plate. The use of 
pins attached to the stripping 
plate is usually advisable in 
such cases. Fig. 114 shows 
the plate with the gate con- 
structed in this manner, but 
the pins are stripped so that 
the moulder must exercise 
care not to damage the mould 
when lifting it from the strip- 
ping plate. When using pat- 




Fig. 116. Two Methods of Arrang- 
ing Patterns and Stripping Plates. 



terns of very intricate shape, where the body of sand is sur- 
rounded by portions of the pattern and is of such shape that it 
needs support, the method employed is known as "stooling." In 
this method of moulding, the pendant or hanging sand is sup- 
ported by the stool, while the flask with the mould is withdrawn 
from the pattern. This will be explained more fully in the fol- 
lowing detailed description. 



loli 



Foundry Moulding Machines and Patlirn Jiijuipintnt 



'I'd illustrate this nutliod of iiKmldint;:, I''i.i,airc 120 shows 
a jolt squeeze stripping plate moulding machine, which is 
especially adapted to this particular ty]>e of work. 




^-B 



Fig. 118 




Fig. 119 



Jnll Stripper Moulding Machines 15.'} 



Fio-urc 117 is a cross section drawing of the drag of an 
aiUomol)ilc- tlywiicci i)aiu-rn. while Figure 1 U> show> a cross 
section of the cope pattern. 'Jhe casting produced is shown 
in outline in Figure 118. It is o!)vious that the sand between 
the rim and hub of the drag half of the mould, and also the 
])odv of hanging .sand in tlie coi)e will reiiuire supports when 
strippiuij- the ])attern from the mould. The drag and cope 
l)attern ecpiipments consist of sub-plates .\. which are bolted 
and doweled to the jolt table. The Stripping plate P>. by 
means of which the Hask is lifted or drawn from the pattern, 
and which rests on the sub-plate .\. is elevated by means of 
])ins at each end of the sub-])late. as well as at the rim of 
the flywheel C\ as the same ])rinciple is applied to both the 
cope and the drag moulds, it is necessary to describe only the 
drag part of the i)attern. The sub-jjlate has a central projec- 
tion extending u])ward and forming the hul) of the flywheel, 
and the corej^rint of the hub core. 

TIk- rim of the flywheel i)attern consists of a ring with 
a nuiltii)le number of downward extending lugs, by means of 
which it is securely fastened to the sub-plate A, each lug 
extending thru the holes in the slri])ping plate 1>. 

Tho hub and rim of the pattern should be cast integral 
with or bolted to the sub-plate, and remain stationary while 
the stripping plate 1> is being lifted, thus strii)ping or drawing 
the mould from the hub and rim. The pendant ])art of the 
mould is supported by stripping plate W during this operation. 

It will be noted that the stripping plate lifts the flask 
and at the same time strips the hub of the pattern from 
around the center of the hub and the inside and the outside 
of the flywheel rim. 

To ])roduce good moulds and consecpiently sound castings 
it is necessary not only to be able to strip this type of pattern, 
btit also to make sure that the sand is sectu'ely held in posi- 
tion by the stool plates, while the mould is being lifted from 
the stripping plate. It is also necessary to provide a means 
to instire the sand being secttrely held while the motdd is 
carried ;'nd placed on the ]iouring floor; this is accomplished 



154 



Foundry Moulding Machines and Pattern Equipment 



by casting ribs on the flask, as shown by the dotted lines in 
FigH-ire 117. The section of these ribs should be tapered, the 
point next to the pattern decreasing to a size about Y^", and as 
close to the pattern as will permit a uniform ramming of the 
sand over the entire surface of the pattern. The distance 




Fig. 120 A Jolt Squeeze Stripper Machine. 



between these ribs and the pattern should be not more than 
I/2". It is important that the ribs referred to be substantial, 
so as to avoid vibration which would destroy the mould while 
being jolt rammed. 



Jolt Stripper Moulding Machines 



155 



The Jolt Squeeze Stripper Machine 

There are also Jolt Stripper Machines which have the 
squeezer operation embodied in the machine, and a discussion 
of the ^.dvantages to be gained by their use is in order here. 
The addition of a squeezer head and a squeezing cyhnder 




Fig. 121. A Jolt Squeeze Stripper Machine with the Stripping Plate 
in the Raised Position. 

naturally makes the machine more expensive and does not 
add materially to the speed of operation, since it is possible 
to butt off the mould by hand in about the same length of 
time that is required to pull the squeezer head forward. 



Foundry M'luldiiiii Mtjcliiiifs cud Ptiltrr)! Equ-ipmnU 



s(|ueczc' the mould and then push the sciueezcr head back 
ai^ain. 'I'he a(l\anlage. therefore, is not primarily one of speed, 
hut ratlur one of (|ualily. In ramming the sand ])y jolting 
and hand hutting oiT. a varial)le human element enters into 
tile deiisilv of the sand in the mould, it is natural, as the 
(lav progresses and the fatigue of the worker increases, that 
he should ram the sand softer, or if he is an unusualK' con- 
scientious worker and realizes the tendency of soft ramming, 
lie will prohabK- overdo the matter and ram the moulds 
harder than he did earlier in the day. In either e\-enl the 
result is non-uniform rannning of the day's moulds, and in 
the dillVrent ])ortions of the same moidd. These variations 
are slight and })roduce onl\- a relati\ely slight ditference in 
the shajx' and weight of the castings. On work which it is 
not necessarv to hold to exact linn'ts, the dit^'erence might 
ne\er ])n/ve serious, hut the ])atterns mounted on stripping 
])late machines are generall}' used in large <|uantities and the 
machine shops are ecpiipped to handle them rapidly. Con- 
sider for instance the automobile piston illustrated in Figure 
114 'i'hese ])istons are made entirely in green sand and are 
hutted (IT hv hand. Slight variations in the density of the 
sand cause slight variations in the outside size of the i)iston 
at the head end. This causes more metal to be turned off 
and increases the machining time. The machinist is able to 
do more ])ieces per hour when the pistons are perfectly round 
and are furnished with the minimum amount of finish metal 
0:1 then I. h'igure 1.^2 illustrates a ])attern which e.xemplities 
another ])hase of the importance of uniform rannning. The 
])att('rn tliere shown pi'oductd one half of th.' symmetrical call- 
ings. 'i"he u])])er point of the jiattern was used as a jigging 
l)oint and the jigs were made to locale from this portion 
of the pattern. It was found that when jolt rannning and 
hand butting off. the distance from one ])oint to the other 
on the rough casting varied from 1/64 to l/vi2 of an inch. 
'Jdiis caused nnich trouble with the jigs, and eventually was 
overcome 1)\- the use of Jolt .Scpieeze Strii)per Machines. 



Jolt Stripper Moulding Machines 157 

'ilu'sc examples arc tyi)ical of practically all jMhs mounted 
on the Jolt S(iueeze Stripper Machines, since they are all 
produced in large quantities and the machine shoj) is e(iui])ped 
with accurate jigs for handling them. 

In th.eor\- as well as in ])ractice, the addition ol the 
s(|ueezing ojjcration to the jolt ramming operation makes for 
unifornnt\ oi results. Not only is each mould identical with 
each other mould, hut also the density of ramming is uniform 
from too to hottom of the mould. I'Mgure 126 illustrates graph- 
ically the reason for this fact. A jolt rammed mould is 
densest at the ])attern plate, decreasing to such a small den- 
sit\' at die top of the flask that hand hutting otT is recjuired, 
while the mould which has only been squeezed is generally 
accompanied hy the reverse effect, that is, the mould is denser 
at the s(|ueezer hoard and sotter turther 1 rom the S(|ueezer 
hoard, requiring, in fact, some hand tucking near the pattern 
and jiattern plate in most cases. The mould which has been 
jolt rammed and squeezed conihines the good ])()ints of both 
and eliminates the hand work of both. The jolting takes 
the place of liand tucking arotmd the })attern. and the squeez- 
ing supplements the jolting ()])eration so that hand butting off is 
eliminated. The total result of the two ojx'rations then is 
to produce a mould, the density of which is jiractically imiform 
from top to bottom as well as over the entire surface of the 
jxittern and j)attern plate. 

In the tyj)es of machines ])reviouslv mentioned, it is 
always necessary to ])erform some of the operations by hand 
On the Jolt Squeeze Stripper Machine, however, the machine 
performs all of the essential ojierations, and the operator 
merely controls the machine. The natural result is that the 
100% i)Ower machine ])roduces a larp-cr nnmlier of satisfac- 
tory moulds than those types of machines which require som 
steps to be performed by hand. 'Jdiis type of machine pos- 
sesses, therefore, not only the highest ability to produce cast- 
ings of uniform size and shape, but also to produce them in 
the largest quantities. The.se advantages offset the disadvan- 
tage of the higher cost of the special patterns, pattern plate 



158 



Foundry Moulding Machines and Pattern Equipment 





Fig. 122. Placing the Flask 
Around the Pattern. 



Fig. 123. Squeezing the Mold. 





Fig. 124. Stripping the Mold. 



Fig. 125. Lifting the Finished 
Mold from the Machine. 



Jolt Stripper Moulding Machines 1^ 



and stripping plates which are necessary, and of the time 
required for changing patterns which involves, of course, 
changing the stripping plate also. These disadvantages, how- 
ever, are not present when the machine can be kept con- 
stantly at work at full capacity on one pattern, for then pat- 
tern changing becomes unnecessary and the greater pattern 
expense is distributed over such a large quantity of moulds 
that it really becomes a low figure when expressed in terms of 
pattern cost per casting produced. 

Operation 
For those who are not familiar with the method of pro- 
ducing moulds from the Jolt Squeeze Stripper type of Mould- 
ing Machine, the four views on the opposite page depict four 
stages of the operation. The upper left hand view shows the 
operators about to place the special cut flask around the pat- 
tern on the stripper plate. It will be noticed that the squeezer 
head is pushed back out of the way, and does not interfere 
with the locating of the flask. The second illustration, in the 
upper right hand corner, shows the squeezer head pulled 
forward into the squeezing position and the table raised in 
the act of squeezing. In moving forward, the squeezer head 
strikes off the surplus sand which remains above the top 
of the flask after it has been jolt rammed, and the squeezing 
operation compresses this sand the amount of the squeezing 
stroke, in this case about 2". The squeezer head is so 
adjusted that at the completion of the squeezing operation 
the sand is level with the top of the flask. The figure at the 
lower left illustrates the next operation in producing the 
mould. The squeezer head has been pushed back, the vibrator 
placed in operation and the mould stripped upward from the 
pattern. It will be noticed that the flask pins are fastened 
to the pattern plate so that they are stripped as well as the 
pattern, thus permitting the finished mould to be lifted from 
the stripping plate more rapidly, as it need not first be disen- 
gaged from the pins. The lower right hand figure shows 
the two operators removing the finished mould from the strip- 
ping plate which is ready to be returned to its initial position. 



100 



Foundry Mouldinti Macliinrs and Pattern Equipment 



1 
























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s_^ 


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XtiA 


f^ 










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7d 


fWi«: 


f tf 


^ 












/ 
















L 












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V 
















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V^ 






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'y 




















V 


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r^ 




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M£/a^r OF F14SK 



Fig. 126. A Curve Showing Graphically the Density of Ramming 

Produced as a Result of Both Jolting 

and Squeezing. 



CHAPTER XI 
Pattern Equipment 

The nuijority of patterns originally made lor floor mould- 
ing can be mounted for use on Moulding Machines. In some 
cases it will he necessary to provide cores or loose pieces to care 
for overhanging lugs, but it is nevertheless true that the great 
majority of the patterns made for tloor moulding can be moimt- 
ed for machine moulding. On the other hand, a more satisfac- 
tory tyj)e of pattern construction may be had by originally con- 
structing the pattern together with the plate. The building 
of the pattern at the same time the plate is built, offers as ad- 
vantages, if both are made of wood, rigidity and strength of the 
pattern, which means less pattern upkeep and longer pattern 
life. Patterns made for machine moiniting, that is, for Plain 
jolt or Roll Over type of machines, sometimes cost more and 
sometimes less, but, on the average, cost about the same, 
vvhethe'- made for floor or machine moulding. 

Too often the design of the pattern is left entirely to the 
l)aitern maker, who. in deciding the type of pattern to be 
made, is in reality determining foundry practice. There are 
many pattern shops which make a specialty of patterns for 
machine mounting. 

These pattern makers, wlio are specialists in their line, 
are better titted than anyone else to decide upon such ques- 
tions as the method of moulding, and they are fully com- 
petent to design and mantifactiu'e equipment which v/ill give 
satisfactory production when used with moulding machines. 
On the other hand, there are pattern shops which have not, 
as yet. made a study of the moimting of ])atterns for machine 
motilding. and who are not in direct touch with the foundry 
in which the patterns are proposed to be used, ft is um'air 
to these i)atternmakers to expect them to produce the best 
designs of patterns when they are not familiar with such fac- 
tors as the number of castings to be made, the portions which 
are to l)e machined or jigged, or the available foimdrv equip- 



Kil 



Foundry Moulding Machines and Pattern Equipment 



ment, including, junong other items, the available moulding 
machine for producing the moulds. It is to the interest of 
the producer of the castings to see that his patterns are prop- 
erly designed for the most economical production in the foundry 
as well as in the machine shop. It is the manufacturer also 
who knows the quantity of castings desired from each pat- 
tern, and since this determines the amount of study and 
time which may justifiably be spent upon a pattern, it is an 
important factor which should be utilized to its fullest extent. 
The essential fact to bear in mind is, that the making of 
the drawing, making of the patatern, and the making of the 
castings are not separate, unrelated steps but that each one is 
related as in a chain, joined to the link on each side of it, and 
that the process of transferring the designer's ideas from his 
brain to finished product is in reality one operation. 




Fig. 127. Correct Mounting of a Fragile Pattern on a Pattern Plate. 

Pattern Materials and Construction 

Patterns are divided into two general classes, wood and 
metal. The material used in the making of a metal pattern 
may be brass, aluminum, white metal or iron, depending, of 
course, upon the size, and whether or not the pattern in 
moulding is to be handled or fastened to the table of the 
machine. Metal patterns are made from master patterns, 



Pattern Equipment 163 



which, for machine mounting, should be provided with the 
necessary ribs to reinforce any weak portion of the pat- 
tern. It is well, also, where possible, to provide suitable lugs 
or bosses (preferably inside the profile of the pattern) for 
fastening the pattern to the pattern plate, although in some 
instances the pattern and pattern plate are cast integral. The 
necessity for rigidity of construction cannot be too strongly 
emphasized in the making and mounting of patterns that are 
to be used for jolt machine moulding, as the pattern that is 
so made as to permit a springing action to take place while 
the machine is being jolted, will cause a vibration that will 
prove very detrimental to the proper packing of the sand, 
and if such a pattern is used, the mould will be full of cracks 
or other imperfections. Therefore, considerable stress must 
be laid upon the importance of properly reinforcing the fiat 
surfaces of the pattern in such a manner as to prevent 
vibration. 

The pattern should not be designed until the style of the 
moulding machine for producing the mould has been deter- 
mined, after which, consideration should be given to the proper 
size of flask. In determining the size of flask that should 
be used in connection with the moulding machine, it is well 
to keep in mind the fact that a machine rammed mould, 
made in a suitable flask, does not require as large an amount 
of sand between the pattern and the flask as has been the 
common practice in the foundries making use of a more 
fragile type of flask, or in those making use of the ordinary 
v/ood flask. 

It should also be noted that a larger castiniT can be 
made in the same flask on the moulding machine than on the 
floor. The decreased sand allowance between t-ie pattern 
and the flask is possible because the motion of the machine 
is more smooth and regular in rolling over than is the roHing 
over by crane, where the flask is frequently balanced on one 
vomer as it is being rolled over. 

It is well to point out the necessity of considering the 
advisability of producing the mould in a rectat!?:i'!ar liask, 



I (14 



Foundry Mouldinf, Machiiu's and Pattern Equipment 



i. c. wliflht'i" iir nui \\\c (|u;uiliu- <il castiiij^s to l)f ukkU- ironi 
the paltcrn is such as would warrani llic iiiakii\j uf a llask 
of a special shape, foUowiuji^ the outline of the pattern, com- 
monly Inown as a "cut" flask. This matter of llii' (lesijru 
cf flasks is covered more tullv in Chapter X I 1 . 

Metal Patterns and Pattern Plates 
As has heen pointed out. when niountin_<i;- jialterns which 
are to Ix' used on jolt moulding machines, extreme care should 
he taken to see that the ])attern is thoroughly reinforced 
and free from all i)ossil)ilitv of a springing action taking 
])lace in the ])attern itself while the mould is heing jolted. 
]*atter;is tor use on this l\i)e of machine, and from which 




Fig. 128 



Fig. 129 




Fig. 130 

a large (|uantitv of castings are to he ])roduced. are usually 
made of metal and mounted on iron ])lates. The thickness 
of the jilates should not he decided until afti'r determining 
the height, in order that thc\- mav conform to the moulding 
machine on which tlu-v are to he used. Where it is possihle, 
lhe\- should he made dee]) and hollowed out in the hack, also 
reinforced 1)\' rihs riuming in hoth directions, and. if the plate 



Pattern Equipment 



165 



can be irade of sufficient height, holes should be provided on 
the sides, suitable for attaching clamps to hold the bottom 
board and flask to the plate while the mould is being rolled 
over. 

Figures 128, 129 and 130 clearly illustrate the high state of 
at^^ainment in the art of pattern making. The patterns are of 
a design requiring the highest grade of workmanship, in order 
to produce the profiles which will maftch and maintain the 
uniformity of section that is required in this particular type 
of casting — the section in many cases being not more than 
3/16" in thickness. 

In Figure 131 are shown tlie cope and drag halves of a 
metal pattern, mounted side by side upon the table of a Roll 
Over Jolt Moulding Machine. A careful study of this view 
will convince the reader that this style of operation is econom- 
ical where the pattern is of a length to permit its being 
used in this manner. In the view here shown it will be noted 
that sufficient blocking has been provided below the pattern 
plates to make the top of both cope and drag halves of the 
flask the same distance from the table of the machine. 

The location of the pattern on the pattern plate, when 
the two are made separate, is worthy of much study, since 
improper location will result in a mismatched cope and drag. 
This defect will cause an undue amount of chipping, or, if it is 
bad enough, will scrap the casting. In matching cope and 
drag halves on separate plates, the only safe procedure is to 
work from the pin centers, which 
must be drilled before the pat- 
tern is mounted. This is necessary 
because a center line can be drawn 
thru the pin lioles more accu- 
rately than the j)in holes can 
be located on the center lines. 
The center line adjoining the 
two pin holes is perpendicular- 
ly bisected, and these two cen- 
ter lines then form the basis of a Pig_ j^j 




166 Foundry Moulding Machines and Pattern Equipment 

system of measurement by wliich the two halve? of the pattern 
are similarly located. 

Machine moulding is so thoroughly a part of the auto- 
mobile industry that very little comment is necessary upon the 
manner in which patterns are made, and the views which 
show automobile castings are used only for the information 
of those other foundrymen who are not familiar with the 
progress that has been made in the automobile foundries. 




Fig. 132. Two Metal Patterns Mounted Side by Side on a 
Roll Over Jolt Machine. 



W'ood Patterns and Pattern Plates 

Therefore, in order to show the use of the jolt moulding 
machine in plants other than the specialty foundries, and the 
gain to be made from their universal use in foundries, illus- 
trations are shown and a full description given of the method 
of making and mounting wood patterns upon wood plates ; 
also of the practice in some foundries, where a universal 
plate is used and patterns of all shapes and sizes are mounted 
on the plate, in order to till the standard size flask provided 
for the statidru-d pattern plates that have been adopted. 



Pattern Equipment 



167 



FigTjres 133, 134, 135 and 136 show several patterns mount- 
ed on wooden plates. They also show the condition of the 
patterns after hundreds of castings have been made. These 
patterns were used on a medium size Roll Over Jolt Moulding 
Machine. 




Fig. 133 



Fig. 134 



The group of patterns shown in Figures 168 and 169 is 
illustrative of the best method of making patterns for use on 
Jolt Squeezer Moulding Machines. These patterns were orig- 
inally laid out and made for jolt moulding; the patterns and 
plates have been constructed together (the patterns being 
built solidly into the plate) making both the plate and the 
pattern more durable than when made separately and fastened 
together by means of bolts or screws. It has been fully dem- 
onstrated by cost records that a pattern of this description 
can be made at a cost not exceeding that of making the same 
pattern for floor moulding, and that the life of the pattern is 



onjjcr. 




Fig. I.i5 



Fig. 136 



168 



Foundry Moulding Machines and Pattern Equipment 



Jobbing foundries are confronted with the necessity of 
making use of patterns which the customer sends them and 
which are usually made for floor ramming. If the foundry- 
man desires to make the moulds on a moulding machine, it is 
necessary to provide plates upon which he can mount the pat- 
tern. This situation has been met in some foundries by the 
use of master pattern plates made either of steel or of wood ; 
if made of wood, they are usually edged with metal cleats 




Fig. 137. A Wood Pattern on a Wood Plate with the Core Box 
on the Right. 



upon which the flask is to rest. These cleats also protect the 
wooden plate. These master plates are provided with center 
lines which make it a simple matter to align the patterns that 
are placed thereon. 

These center lines are used to locate one half of a set 
of dowel pins, the other half being mounted in the loose pat- 
tern, which will be placed on the plate temporarily. While 
this method docs not ofifer the advantages that are ofifered 
by building the plate and pattern together, namely, rigidity of 
construction and consequent low pattern upkeep, yet in job- 
bing shops it is a profitable method of handling work in 
those cases where the pattern is furnished and only a few 
castings are to be made. 



Pattern Equipment 



169 



From the views shown in Figures 138, 139, 140 and 141, it 
will be seen that there can be mounted on the plates many 
different shapes, styles and sizes of patterns, the object being 
always to fill the plate with patterns in order to make use of 




Fig. 138 Fig. 139 

all the available space in the flask. The views of the plates 
shown in Figures 140 and 141 especially emphasize this possi- 
bility, as there are several different styles of pattern poured 
from one gate. The patterns shown in these figures, with 
the exception of the gear, are so-called "flat back" patterns, 
requiring no part of the pattern in the cope. By referring 
to Figure 141 it will be noted that the cope-plate, standing 
alongside the drag plate, is provided with a depression that 




Fig. 140 Fig. 141 

aligns with the gear shown on the drag plate; this depression 
produces the proper shaped cope half of the mould for the 
ffear. 



170 



Foundry Moulding Machines and Pattern Equipment 



The plate shown in Fignre 140 is well covered by n 
number of small patterns, all of them being shallow. It will 
be noted, however, that on the floor adjacent to the pattern 
plate are patterns having a greater depth. By taking off the 
patterns now moulded on the board these deeper patterns 
may be easily mounted and located by means of pins. The 
particular plates shown in these four figures were made to be 
used in connection with a Roll Over Jolt Moulding Machine. 




Fig. 142 Fig. 143 Fig. 144 

Comparison of Machine and Floor Patterns 
In order to bring more clearly before the reader the 
possibility of the great saving to be made, by making the pat- 
terns for machine moulding originally, there are showai in the 
following views the casting to be produced, the pattern as it 
was made for use on the moulding floor, and also as it \vas 
later mounted to be used on either the Plain Jolt or the Roll 
Over Jolt Moulding Machine. 

Figures 142 and 143 (combined) show a casting difficult 
to make, and the manner in which the pattern was made for 



Fig. 145 



Pattern Equipment 



171 



hand ramming on the moulding floor. Observe the "stop- 
off" piece used in order to hold the shape of the pattern 
while the mould was being rammed, which was difficult to do 
regardless of the stiffening member. 




Fig. 146 

Figure 144 shows the manner in which a new pattern was 
later mounted on pattern plates for use on Jolt Moulding 
Mathines. The difificulty experienced in the producing of a 
casting straight and true to pattern was entirely eliminated 
by the use of the pattern plates. 

Figures 145 and 147 show large and difficult castings. Fig- 
ures 146 and 148 show patterns as they were originally made 
for use either on the floor or on Jolt Moulding Machines. 
However, it was possible to make only the drag half of the 
mould on the machine when using the patterns without mount- 
ing them on pattern plates. This was accomplished by placing 
the drag pattern flat on a plate on the table of the machine, 
and after jolt ramming the drag half, the flask and pattern 





^^^^iS- 



Fig. 147 



172 



Foundry Moulding Machines and Pattern Equipment 



were rolicd over and placed on the foundry flot)r, and the cope 
half of the pattern was rammed by hand in the usual way. 

Figure 149 is still another view, which again emphasizes 
the advantage to be gained by mounting the patterns on pat- 
tern plates, especially fragile patterns. 

In the early days of ma- 
chine moulding there was de- 
veloped a method of mount- 
ing patterns known as "shell 
patterns." Such patterns 
when mounted for machine 
use were usually made for the 
production of castings in large 
quantities, the cope and drag 
halves being mounted on sep- 
arate machines — usually the 
drag on a roll over type of 
machine, and the cope on a 
stripping plate machine. The 
method devised was such as 
to make use of the shell pat- 
tern for either cope or drag 
])late. The views shown in 
Figure 150 are of the cope 

and drag patterns mounted 

Fig. 149 




P^""'"' '_3> 




Fig. 150 



Fatlern Equipment 17.'? 



on a stripping plate and roll over machine respective- 
ly. The pattern here shown is a jacket of a hot water 
gas heater, with the shell varying in thickness from 
]/%" to 3/16". The shell pattern was used for the cope 
plate, while a white metal match was made from the shell 
pattern, and used for the drag plate. Foundries producing 
stove castings generally make use of this method of pattern 
niDunting, the details of which are well known to the industry. 

Patterns for Squeezer Machines 

There are several different methods in use for the mak- 
ing and mounting of patterns to be used in connection with 
air-operated squeezer machines. Some of these methods are 
applicable in one case while others are preferable in different 
cases. The various methods of mounting patterns for use on 
the Squeezer Machine are as follows : 



Method of Mounting 


Pattern Cost 


ProditctionOhtained 


Tlard Sand Match 


Small 


Small 


Vibrator Frame 


Medium 


Medium 


:\retal Plate 


Cjreatest 


Greatest 



Suppose that a loose pattern is received at a foundry 
with an order for castings. If only one or two castings are 
desired it is possible for a skillful moulder to make these up 
directly from the loose patterns, using a green sand match, 
but if any quantity is desired one of the methods mentioned 
above will be used. 

Hard Sand Match 

In mounting the patterns for producing a small quantity of 
castings the gated style is used with a hard sand match. The 
pattern, or patterns, are mounted together, joined by metal 
strips which also serve to form gates in the mould. Figure 
151 illustrates such a method of mounting four patterns together. 
It can easily be seen that a follow board must be used with 
this style of pattern; the most commonly used follow board 
is a hard sand match. 



174 



Foundry Moulding Machines and Pattern Equipment 



The material used in niakini,^ the hard sand malcli varies 
although the following formula has been found to give satis- 
faction : To eight parts, by weight, of boiled linseed oil, 
add by weight, one part of yellow oxide of lead. A suffi- 
cient amount of the mixture is added to new moulding sand 
(which should be baked to insure it being thorouirhlv drv") 






aOSkSlirialMMiHr 






Fig. 151. Upper Left— Hard Sand Match; Right— Gated Pattern; 
Lower Left — Drag Mould; Right — Cope Mould. 

to make it the consistency of well tempered moulding sand. 
The gated pattern is placed in the flask and the drag and 
cope rammed in green sand. The cope is then removed and 
replaced with a wood frame, previously prepared for containing 
the match preparation. The surface of the drag and of the 
pattern are then dusted with suitable parting material, and a 
new cope rammed up in the match frame, using the match 
material. The surface of the match is then made even with 
tlie frame, and a bottom board secured in place with screws. 
'I he mould is next rolled over, and the green sand drag 



Pattern Equipment 



17."> 



removed. The pattern can then be drawn, and any portion 
of the match that has been injured by the drawing of the 
pattern can be repaired. The match should then be set aside 
in a warm place for about twelve hours and allowed to become 
hard and dry ; shellac may be applied for the purpose of 
further waterproofing. A gate of patterns, together with the 
hard match and a mould made from the patterns, is shown 
in Figure 151. 




Fig. 152. Upper Left— Drag Mould; Right— Cope Mould; 

Lower Left — Hard Sand Match; Right — Pattern Mounted 

in Vibrator Frame. 



\ ibrator Frame Patterns 

Since the gated pattern must be wrapped thru the sprue it 
is not as rapid in use as is desired, and a modification is intro- 
duced in the shape of a vibrator frame, wdiich is illustrated in 
l-"igin-e 152. The vibrator frame, in addition to the pattern 
and gates, consists of a frame, to which the vibrator may be 
attached. 



176 



Foundry Moulding Machines end Pcttern Equipment 



f 



In attaching vibrator frames to the gated patterns, it is 
necessary only to fasten the two together firmly ; no allowance 
in the height of the pattern is necessary to compensate for 
the thickness of the vibrator frame. 

Match I^latcs 

^Nlatch plates consist essentially of a metal plate, the 
opposite sides of which form the cope and the drag half of the 
mould respectively. Flat plates 
may have the pattern or pat- 
terns attached by means of 
dowel pins with suitable fast- 
ening, both halves of the pat- 
tern first being drilled at the 
same time, and then one halt 
of the pattern being used as 
a jig to drill the plate. Other 
forms of plates are cast of an 
aluminum alloy, and the pat- 
tern and plate are cast inte- 
gral. Figiu-e 153 illustrates 
the first mentioned variety of 
match plate. A thin steel 
plate is cut to the desired 
shape, and the opposite halves 
of the split pattern are mount- Fig. \Si. 

ed on opposite sides of the plate and aligned by means of 
thru dowel pins. The gate is then fastened on and the plate is 

completed. Figure 154 shows 
the method of using the fin- 
ished plate. This method is 
a very satisfactory one when 
the parting line is straight 
and the patterns to be mount- 
ed are simple, but when the 
patterns are of irregular 
shape, requiring an irregular 
Fig, 154. parting line, with hollowed 



I I I I 



III] 






1 i I 1 



I I I I 




I'attern Equipment 



177 



out surfaces on either the cope or the drag, it then becomes 
an ahnost impossible matter to machine a plate of the reqviired 
shape, and the most satisfactory practice is the casting of the 
plate and pattern all in one piece. Figure 135 illustrates a 
plate of this nature. 

In this manner the plate becomes essentially a fin on the 
casting, as the plate is usually made by ramming up a mould 




Fig. 155. Upper Left— Cope Mould; Right— Cope Side of Plate; 
Lower Left— Drag Side of Plate; Right— Drag Mould. 

and separating the two halves by a distance equal to the thick- 
ness of the plate. The procedure of making the plate is a 
simple one, and in view of the universal use of the match 
plate, the process is shown in detail on the following pages. 
The match plate is readily seen to be a reproduction of 
the gated pattern with the plate cast as a part of the pattern, 
the plate occurring at the desired parting line. A very help- 
ful way of considering the match plate is to consider it as a 
fin occurring at the parting line, of a thickness previously 
determined, and confined to the shape desired. 



178 . foundry Moulding Machines and Pattern Equipment 




Fig. 156. The Gate of Patterns and the Hard Sand Match Used in 
Producing the Match Plate Are Here Shown. 




Fig. 157. The Gate of Patterns is Placed on the Match and an Extra 
Length of Green Sand Built On. 



Pattern Equipjnent 



179 




Fig. 158. The Drag Flask is Placed on and Clamped, Ready 
for Rolling Over. 




Fig. 159. The Hard Sand Match is Removed, Leaving the 
Pattern Bedded in the New Drag Half. 



180 Foundry Moulding Machines and Pattern Equipment 




Fig. 160. The Cope is Placed on and Rammed in the Usual Manner . 




Fig. 161. The Cope is Removed but the Pattern is Not Drawn 
at this Time. 



Pattern Equipment 



181 




Fig/162. Wood Forms Are Used to Shape the Ends of the Plate and 
Form the Pin Ears. 




Fig. 163. The Mould is Now Complete and is Ready for the Pattern 

to be Drawn. 



1S2 Foundry Moulding Machines and Faltern Equipment 




Fig. 164. The Pattern Having Been Drawn, the Mould is 
Closed and Clamped. 




Fig. 165. Pouring Must Take Place Rapidly Due to the Thin Sections. 



Fattt-rn E(fuipmn\l 



1S3 




Figt- !<><>• The C>ope Side of the Match Plate. Note the 
Method of Gating. 




Fig. 167. The Drag Side. These Two Views Show the Plate 
Just as it is Shaken Out. 



184 Foundry Moulding Machines and Pattern Equipment 

An alloy coniposerl of 

Zinc 15 per cent 

Copper 3 per cent 

Aluminum 82 per cent 

is frequently employed for match plates used on a Jolt Squeezer 
Mouldino- Machine. These plates must be made thick enough 
to have sufficient strength to resist, without deflection, the 
impact of Jolt Ramming. A second alloy used for the same 
purpose is 

Aluminum 69 per cent 

Zinc 31 per cent 

Both of these alloys have a shrinkage of about 5/32" per foot. 
The standard No. 12 Aluminum Alloy composed of 

Copper 8 per cent 

Aluminum 92 per cent 

is used for match plates which will be used on Plain Squeezer 
Machines, but is not strong enough for match plates to be used 
on Jolt Squeezer Machines. 

In casting match plates there are two difficulties which 
must be carefully avoided. The first is poor gating, which may 
allow some portions of the plate to solidify before metal has 
reached all portions of the plate, and the other difficulty is 
unequal shrinkage in the cope and drag halves of the plate. 
Gating is a very difficult problem, and it should be remembered 
that a large thin plate must be successfully run in a very short 
period o' time. The lower illustration on page 165 shows the 
mould being poured from three ladles. This is neccssar\-, as the 
metal must enter from both sides of the plate simultaneously 
and meet at the center. A long runner is made, extending the 
full length of the pattern plate, with numerous openings from 
the runner into the casting, so that the metal can enter the 
casting thru the entire length at the same time. \\'hen casting 
comparatively large hubs of metal in connection with tliin sec- 
tions, it is advisable to use an aluminum core which is set into 
the mould on chaplets, and has new metal all around it. This is 
accomplished by making a mould from a wood pattern and cast- 
ing it in plaster of paris. The heavy .section, which is to be 
cored out, is then cut away from the other portions of the pat- 



Pattern Equipment 



185 



tern and shaved a uniform amount of either 3/16" or 1/4". 
This plaster core is then used as a pattern and reproduced in 
aluminum which is set into the mould on chaplets, and which 
allows a uniform thickness of 3/16" or 1/4" of metal to be 
poured around it, burning in the chaplets and eflfectually pre- 
venting shrinkage of the large hub on the pattern. 




Fig. 168. A Group of Wood Patterns on Wood Plates. 

The use of brass chills on the cope surface will also solve 
many difficulties encountered in unequal shrinkage of copes 
and drags. 

Figure 170 shows graphically the total pattern and moulding 
costs of producing various quantities of castings from the 
different types of patterns used on squeezer machines. Since 




Fig. 169. These Wooden Patterns Were Built on the Plates. 



186 Foundry Moulding Machines end Falter n Equipment 



the varying factors of pattern and labor cost will be different in 
each fotnidry, the exact ligures will not hold true except for one 
foimdrv. However, the general shape of the curves are the 
same in all cases. The height of the curve at its starting point 
on the extreme left indicates the cost of the pattern and its rise 
as it progresses toward the right is due to labor and fixed 
charges on tlie moulding machine and pattern equipment. In 
drawing up such a curve for his own use, a foundryman will 
determine the average cost of his patterns made by the various 
methods, ihe average labor cost of jiroducing moulds by the 
various methods and his own hxed charges. He will then be 
able to read from his chart the most economical type of pattern 
to be made and used for any given ((uantity of castings. 

Patterns for Stripping Plate Machines 

The patterns used with this type of machine are sur- 
rounded by an accurately fitting stripping plate, which is so 
closely fitted that there is not room for satid to get in between 
it and the pattern. This requires that the stripping plate be 
fitted to the pattern by hand, and in considering patterns for 
these machines, the stripping plate should be regarded as a part 
of the pattern equipment. It is for this reason that the cost of 
pattern equipment on the stripper machine is high, and that 
more skill is required to make them. Two general types of 
patterns for stripping phite machines are illustrated in Figure 
116. A.ri additional method of handling difficult patterns 
is by means of "stooling." A description of this method is 
given in the chapter on Jolt Stripper Machines on jiage 152. 
The contents of this chapter emphasize throughout the necessity 
of planning the style and construction of the pattern at the 
same time that the method of moulding, and the quantities, are 
being planned. The only too common practice of sending a 
blueprint to the pattern shop, with instructions to deliver the 
jjattern to the foundry, is essentially wrong. The Planning 
Department should take care of the production of the casting 
from its beginning in the mind of the designer, throtigh the 
Drawing Room. Pattern .Shoj). h'oundry and to its linal destina- 
tif»n. 



188 Foundry Moulding Machines and Pattern Equipment 






Fig. 171. A Group of Typical Small Flasks of Good Design. 



CHAPTER XIT 
Flask Equipment 

Of exceptional importance to the successful operation of 
moulding- machines is the providing of suitable flasks. It is 
a waste of time and money to attempt the production of good 
moulds on moulding machines without giving the proper con- 
sideration to flask equipment. There are many difficulties 
encountered with the ordinary flask equipment in use in the 
foundries producing moulds by hand ramming methods and 
much loss is occasioned by the use of flasks that are burnt, 
or that have become loosened by the severe handling incident 
to foundry practice. Flasks in this condition should not be 
used, even in hand-moulding, and the time consumed in addi- 
tional care, as well as the loss occasioned by their use, would 
more than offset the loss incurred by scrapping the old flasks 
and making new ones. Those foundries that are accustomed to 
the use of wood flasks only, find it rather difficult to see imme- 
diately the necessity of changing their viewpoint to coincide with 
modern founding. It had been their practice to nail together 
roughly a set of flasks for almost every pattern that was to be 
used, tliii king that the cost of wood flasks was small when com- 
pared with that of iron flasks. Little attention was given this 
subject nor were many attempts made to standardize the flask 
ecjuipment in order to reduce to a minimum the stock of flasks 
necessary to carry on the foundry operations. 

The introduction of moulding machines has made possible 
the standardization of flasks in such a manner as to reduce 
the cost of flask equipment below that of the old style methods, 
so that a better and more durable flask can be made. Such 
flasks, when made of grey iron or of steel shapes and given 
the propel consideration in handling, are practically indestructi- 
ble and, therefore, in the end, are the most economical that can 
be made. 

Design of Flasks 
The subject of flask equipment is vitally important in order 
to bring those who are inexperienced in foundry moulding 



\w 



Fou>idr\ Moulding Machine} and Pattern Equipment 




machine operation, to a full appre- 
ciation and realization of the im- 
l)ortance of good flask equipment 
in producing moulds by machine 
methods ; and therefore, the fol- 
lowing views are shown to illus- 
trate the styles of flasks that are 
largely used in moulding machine 
production. The shape and size of 
the flasj^ arc the first things which should be determined in con- 
siderinfj the design. While the ordinary rectangular flask is com- 
monly used in the majority of cases, nevertheless it is frequently 
advisable to make what is known as "cut flasks," that is, flasks 
which follow, to some extent, the contour of the pattern. Figure 
172 illustrates a rectangular flask, containing one casting per 
mould, und represents ordinary practice in iron flask desigii. 



Kift. 172 





Fiji. 173 Fig. 174 

Contrasted to this. l-"igure 173 and Figure 174 illustrate the 
design of a cut flask for producing two of these same castings 
per mould. It will be noticed that the corners are cut away, sav- 
ing expense and weight of iron, and the handling of extra sand . 
also, thct the block of sand shown in the center of Ingure 173 
has a double use, that is. it serves to support the mound of sand 
necessary when making each of the two castings, whereas in Fig- 
ure 172 the mound of sand is used only once. It is easy to see 
that the weight of flask equipment to be handled is less per cast- 
ing in the case of a flask designed as shown in Figure 173, and 
also tJTit tlie amount of sand to be handled per casting is less. 



Flask Equipment 



191 



The shape and dimensions of the flask having been decided 
upon, iho material of which it is to be constructed is the next 
consideration. Formerly, wooden flasks were preferred rather 
than iron flasks, in many foundries, and the process of changing 
to the more satisfactory iron flask has been rather .slow. Today, 
however, grey iron and rolled steel flasks are quite commonly 
used and the satisfaction which has attended their use is well 
known t() the foundry industry. 




Fig. 17.S. 

Soine txpical iron flasks 
are illustrated in Fi^nu'es 
175. 176. 177. 178. 180. 
181 and 182.- In adopt- 
ing a standard design of 
flask, to be used in a variety of sizes with jolt ramming 
machines, the following designs are submitted as representing 
the result of satisfactory use. Figure 179 is a drawing suitable 
for use 111 making flasks ranging from 20" to .W" in length, and 



Fig. 176. 




v.r2 



Foundry Moulding Machines and PatUrn Equipment 



REAM-J 





OOOOOOOOO 



ooooooooo 



5—1- 



LENG TH OF FLR SK 
Z0TO4-0 INCHES 



J^^ 



ii 



PROVIDE. COPE FLftSKS WITH 
A RETAINING SAND LEBGE 



CROSS SECTION OF FLA5K UNDER 25 INCHES IN WIDTH 






CR0S5 SECTION OF FLf\5K FROM aSToAO INCHES IN WIDTH 



F 



,^ 



<i 

CROSS SECTION OF FLASK OVER 15 \NCHES IN HEICKT. 

Fig. 179. Standard Drawing for Flasks, 20" x 39" in length. 



Flask Kquipmcnl 



193 



of appropriate widths and moderate heights. It will be noticed 
that the flask is fully dimensioned except for the inside length, 
width and height. 

Figures 183 and 184 illustrate drawings suitable for flasks 
ranging in length from 40 to 59 inches and from 60 to 80 
inches, of any widths and any heights. 




Fig. 180. 



Fig. 181. 




Fig. 182. 

By selecting the proper drawing and using the section which 
corresponds to the width desired and also using the design cor- 
responding to the height of flask desired, this set of three 
flask drawings may be used to make any flask from 20 inches in 
length up to 80 inches in length by 80 inches in width and of 
any desired height. 

The holes shown in the side walls of the flasks are for the 
purpose of venting the green sand and are spaced at any con- 
\enient distance. They may also be used in bolting the bars in 
cope halves. 



Foundry Mnuldin-' Machiyu-- a'-d Fat!rr>' E'luipmrnf 




CROSS SECTION OF FLRSK OVER 20 INCHES IN HEIGHT 
FLR5KS OF THIS HEIGHT SHOULD nIVit STIFFENING RI85 
SPflCEO ABOUT II INCHES APART AROUMD THE FLASK 



Fig. 183. Standard Drawing for Flaslis, 40"— 59" in length 



Flask Equipment 195 



Tlie use of tlie flask pins requires some mention here in 
order to explain clearly the reason for the four pin hole loca- 
tions. The ideal place for the location of pins is directly 
heneath the trunnions, but since their location at this point is 
attended by the inconvenience of using closing pins of very 
short length, due to interference with the trunnions, it is advis- 
able to locate the pin holes to one side of the trunnion, care 
being taken to keep them as close to the trunnion as is prac- 
ticable. The location on all three of the standard drawings 
shown is 2^" from the trunnion center, and it will be noticed 
that one ear is provided of suitable size to take both pin holes. 
In actual use, however, only two pin holes are used, these two 
being diagonally opposite each other. Of course, cope flasks 
nuist b(i drilled opposite from the drag flask and, in some 
cases, wl^ere the same flask pattern will be used to make both 
cope and drag flasks, the lug for all four pin holes is necessary. 
On flasks, which are to be used only as copes or only as drags, 
there is- a possibility of damage to the pin hole, making it advis- 
able to use the other holes, so that, in all cases, only two holes 
need be drilled and the other two locations are held in reserve. 

While the location of both the pins and trunnions on the 
ends of the flask is attended by many advantages in handling 
the flask, yet in some cases it is advisable to locate the trun- 
nions on the sides of the flasks and the pin holes on the ends. 
In other cases, this is reversed by placing the pin holes on the 
sides and the trunnions on the ends. 

The jig shown in Figure 185 is used with the standard flask 
drawings for drilling flasks of any length. When flasks of a 
large range of sizes are to be drilled it is advisable to make 
two jigs, as it is very awkward to handle a large jig on a 
relativeh' small flask. In using the jig, the slip bushings are 
fitted into the common hole at the end of the jig and the appro- 
priate hf Ic at the other end. After one hole has been drilled 
it is advisable to place a tightly fitting plug through the jig 
and hole in order to locate the second hole accurately. 

Bars used in the cope flasks may either be cast in one piece 
with the flask, or cast separately and bolted in. When using 



1% 



Foundry Moulding Machines and Potlrrn Equipment 




l-4kJ 



CROSS SECTION OF FLASK UNDER BO INCHES IN WIDTH 




CROS^ SECTION OF FLBSK OVER 20 INCHES IN HEIGHT. 
ri-RSKS OF THIS HEIQHT SHOULD HftVE STlFFtNlNC R1B5 SPRCEO 
ABOUT It INCHES BPftRT RROUND THE FLRSK. 



Fift. 184. Standard Drawing for Flasks 60" -80" in length. 



Flask Equipment 



197 



the bolted construction, attention must be paid to the fact that 
the flask will be jolt rammed and rigidity is important. 

The proper design of flask bars to facilitate the packing 
of the sand underneath them during the jolt ramming operation 
is of importance, as improperly designed bars frequently require 
the use of gaggers, when correct designs would eliminate their 
use. The bar should be located at a uniform distance of about 
1/2'' above the top of the pattern, as it has been found that this 
distance is great enough to allow the sand to be packed uni- 
formly under the bar and yet small enough to hold pockets of 
sand with a minimum use of gaggers. 




Fig. 185. Jig Used in Drilling Flasks. 



The complete flask illustrated in Figure 176 is used in 
connection with the Roll Over Jolt Moulding Machine. In this 
view may be seen the type of closing-pin used, which has proved 
to be the best all around type of pin. Figure 186 is a 
sketch of a closing pin. The use of this particular type of 



198 



foundry Mculding Machines and Pcttern Equipment 



r7=^ 







A" 



TO^UIT 



TO 5U/T 



FLAS/^ P/^ 



closing - pin is much better 
than the old style of fasten- 
ing the pin in the drag halt 
of the mould, as it prevents 
the breakage which was so 
common while the flasks were 
being shaken out and han- 
dled in the foundry and stor- 
age yard. The right hand 
pin is of the design common- 
ly used to locate the flask on 
the pattern plate. Figure 187 
illustrates a pattern used in 
m a k i n g flasks. It will 
be noticed that core prints are used to locate the trunnions 
instead of ramming them up, as is the practice in some found- 
ries. The undercut portion of the pin ears around the pin holes 
is seen to be cut away on the pattern, indicating that in this 
case a cope was used in making the flask, and this portion was 
coped out. The practice of casting flasks in open sand is not to 
be recommended, although it can be done in some cases. 



C£oa//^c ^M 



Fig. 186 




Fig. 187 

Figure 188 shows one type of bottom board that is used 
with grey iron flasks. The bottom board may be either plain or 
supplied with projections, as here shown. The advantages of 
the projections are manv, inasnuich as tlicy make it more con- 



Flask Equipment 



199 




Fig. 188 



venient to release the chains 
when carrying the mould to 
the foundry floor as well as to 
attach the chains after the 
mould has been poured and 
is ready to be taken to the 
"shake-out" floor. While the 
cost of providing the plates 
with the projections re- 
ferred to is greater than that of producing the flat plate, 
nevertheless, when it is considered that the plate is to be used 
continually, it is well to ascertain whether or not the time saved 
in crane service does not far exceed the additional expense of 
providing the extra projections on the plates. 

On smaller moulds, however, which are of a size that 
can be carried away by hand, without the use of a crane, an 
inexpensive bottom board is made by the use of a cast iron or 
steel plate with standard chan- 
nel-iron riveted to its back, as 
is shown in Figure 18^). 

Rolled Steel Flasks 

'Jhe descriptions thus far 
have covered flasks that are 
to be made of castings, either 
grey iron or aluminum . 
There has been a flask devel- 
oped, however, which in mauA- 
respects for certain sizes, is 
better than those made In- 
casting. This particular flask, 
shown in Figures 190 ancl 
191, is made of steel, the sec- 
tion of the flask being de- 
signed especially for produc- 
ing rigidity, by means of ribs which are rolled into the plate. 




Fig. IS") 



200 



Foundry Moulding Machines and PatUrn Equipment 



The manufacturers, realizing that there would be a large 
demand for a light and rigid flask, have provided special rolls 
to produce the various shapes required. The shapes are rolled 
in long bars, and in the manufacture are shaped, by the use of 
a large bending apparatus, to the desired size; the joint is then 
firmly riveted. 




Fig. 190 

By referring to the illustration of these flasks, it WAX be 
seen that there are light malleable castings provided for carry- 
ing the fiask pins, as well as a light section handle casting 
riveted to the corners. 

Mention has been made of the importance of the proper 
flask equipment. It is not too much to emphasize again the 
fact that without the proper pattern and flask equipment, 
machine moulding is practically an impossibility, and yet it is 
not desired to convey the impression that the providing of the 




Fig. 191 



Flask Equipment 201 



proper patterns and flask equipment is a difficult task. The 
fact of the matter is that the proper equipment can be provided 
with very httle, if any, additional cost over that for producing 
the usual equipment required for floor moulding. 

Snap Flasks 

As a large amount of the work produced on air-operated 
squeezer machines is made in snap-flasks, Figures 192. 193 
and 171 are shown to illustrate the different styles in com- 
mon use on those machines. 

The manner in which these flasks are used is clearly set 
forth in the descriptive matter, as well as illustrated in the 
different photographs in Chapters I and IX. 




Fig. 192 Fig. 193 

There is some work of such size and shape as to be 
readily adapted to squeezer-moulding, and yet, because of its 
weight, it cannot be successfully made in snap-flasks. Such 
work is usually made in iron flasks of very light construction, 
as illustrated in Figure 171. 

The flask shown in Figure 175 illustrates one in common 
vise in the aluminum and brass foundry industries. 

What has been said of the above flasks and of their 
adaptation to air-squeezer moulding, can also be said of their 
use on the hand-rammed, hand roll-over type of machine, 
commonly used on such work as does not readily lend itself 
to squeezer moulding. 

Flask design and construction has been discussed here in 
such detail on account of its great importance. When hand 
moulding, and producing from one to five moulds per day from 
each pattern, the loss of one minute per mould, due to faulty 



202 Foundry Moulding Machines and Pattern Equipment 

flask design or construction, is not important, as the aggregate 
time lost is small. When machine moulding and producing 
one hundred moulds per day from a pattern, the loss of one 
minute on each mould then becomes an aggregate loss of one 
hundred minutes, which is a very serious matter, indeed, as it 
represents 20.8% of the total time of an eight-hour day. No 
effort has been made to discuss the construction of special 
flasks when the quantities of castings produced warrant the 
expense. When high production is to be obtained the standard 
flask, as described in this chapter, should be altered in any way 
that will decrease the time of making the mould, or will increase 
the quality of the casting. In short, the rules to be followed 
in flask design and construction are: 

Spend time and thought on flask desi(j)i. 

Spend money on flask equipineut and it leill more than pay 
for itself. 



CHAPTER XIII 
Machine Moulded Cores 

The exceptional demand of the automobile industry for 
castings, in addition to forcing the use of a method that was 
speedier than the method in use a few years ago, also made 
necessary a way in which to produce the tremendous quanti- 
ties of dry-sand cores that were required for the production 
necessary to meet the demand. 

There are a number of different styles of moulding 
machines that are used to advantage in the core room. There 
are also a number of the smaller cores that can be made by 
hand on the bench faster than when made on moulding 
machines. Therefore, it is the medium large, yet delicate and 
intricate core with which this chapter will deal. 

The subject of core-making is one of such magnitude that 
the little given in this chapter appears insignificant ; it is with 
a keen realization of this fact that the author ventures to show 
and describe a few of the core-making operations, attempting 
only to create in the minds of those who are not familiar with 
the highly developed state of the art, a desire to know more of 
the possibilities awaiting the introduction of the moulding 
machine into the core-room. Foundries producing high grade 
castings have adopted a rigid system of core-inspection by 
which the various individual cores are measured by gauges, 
having the allowable limits. In addition to the gauging and 
inspecting of the individual core, extreme accuracy is required 
in the satting, and therefore, to insure the core being accurately 
set. there has been devised a system of assembly jigs in which 
the detail cores are made fast into the composite core assembly, 
and are held firmly in place by pouring lead into the interlock- 
ing holes provided in the different detail cores. Therefore, with 
this explanation, the reader is requested to refer to Figure 194, 



204 



Foundry Moulding Machines and Pattern Equipment 




Fig. 194 



which ilhistrates several 
conipHcated cores that have 
been produced on the 
moulding machine. 

By careful study of this 
view, it will be seen that 
some of these cores are 
made in one piece ; while 
other views show several 
cores assembled together. 






Fig. lOS 


^ '^>!^^^B|^^^^^^^^^^^V 






S^^ 




-■.p^^^^s 



Fig. 196 



Machine Moulded Cores 



205 




Handling Complicated Cores by Assembly and 

Setting Jigs 

iMgure 195 shows clearly 
the manner in which the core 
is assembled. The various 
cores, after being assembled 
into one complete core and 
gauged for accuracy and then 
placed into the mould in the 
ordinary manner, still failed 
to meet the requirements, as 
it was found that a sufficient 
accuracy could not be attained 
^'S- *^^ because of variation, due to 

the cores straining the core-print pockets when being lowered 
into the mould. This condition was overcome by providing 
suitable core-setting jigs, as illustrated in Figures 196 and 
197. Figure 196 shows, in the background, an assembly jig, 
and m the foreground, the assembled core attached to the 
setting jig. Figure 197 shows the manner in which the jig 
is used while lowering the core into the finished drag half 
of the mould. It will be seen from this view that the core- 
setting jig is guided into place by means of the flask pins. 

The style of castings which 
this mould will turn out is 
shown in the foreground. 

The cores illustrated in the 
])re\-ious views were made on 





l*».s 



Fig. 199 



2U6 



Foundry Moulding Machines and Pattern Equipment 





Fig. 200 



the moulding machine illus- 
1 ruled in Figures 198 and 
I'^O. l-roni Figure 198 it will 
he seen that the core has 

a'B '^-^gt^Jf/S^ |M heen rammed on the machine 

Ji^-' i.iJffPBll I W '""^ ^'^^" rolled over, and the 

l)aUerns and loose pieces 
drawn from the main core- 
box, h'igure 199 shows the 
same core after it has been 
lifted to the side of the ma- 
chine, the loose pieces with- 
clrawn and the core-box part- 
ly rolled back in order that 
the complicated core-box may be seen to advantage. 

(jrccn Sand Cores 
Dry-sand piston cores are produced at the rale of six per 
operation on the machine shown in Figure 201, while in Figure 
202, the producing of piston moulds is shown, using the green- 
sand core method instead of the dry sand. 

Figure 202 shows a mould 
for the handling of grey iron 
castings for gas engine pistons. 
This is a good example of 
green sand cores, as thev are 
made on a moulding machine. 
The cores are formed integral 
with the drag portion of the 
mould in a metal core-box. so 
arranged as to produce foiu* 
cores at one cycle of opera- 
tions. This core-box is of 
the split type and is parted 
directly through the centers 
of the cores. The wrist-pin 
bosses are secured to the in- 
side of the bo.x on a center pj^ 201 




Machine Moulded Cores 



207 




line at a right angle to the 
parting Hne of the box. The 
top of the box forms a flat 
surface of sufficient area to 
form the parting surface of 
the mould. The members of 
the core-box are arranged to 
be separated in a horizontal 
liy. 202 plane, by means of a lever 

located at the back of the box. so as not to interfere with the 
movements of the operator. On the ends of the core-box mem- 
bers are provided tongues which slide in grooves in the upright 
ends of the frame. A bearing strip provided at the bottom of 
the box prevents distortion of the box while being rammed. 

This core-box was mounted on a Roll Over Moulding 
Machine and was used in the following manner : With the 
core-box set in the position shown in the illustration, the drag 
flask was placed on the core-box with pins on the core-box 
properly engaging the holes in the flask ears. The core-box was 
tiicn filled with riddled moulding sand and the sand tamped and 
packed on the lower side of the wrist-pin bosses, after which 
the flask was filled and rammed complete. The mould was then 
"struck off," the bottom board clamped in place, and the table 
carrying the core-box rolled 
over. The leveling bars were 
then brought up against the 
bottom board and the auto- 
matic leveling pins locked. The 
bottom board clami)s were 
next released, after which the 
vibrator was started and the 
members of the core-box 
drawn apart by means of the 
lever provided for the pur- 
pose. The flask and cores 
were then lowered to clear 
the core box, and removed Pig, 203 





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Foundry Moulding Machines and Pattern Equipment 




Fig. 204 



from the machine to the posi- 
tion shown in Figure 202. 

Tunnel Segment Cores 
'i'he tunnel segment casting, 
fully illustrated and described 
in Chapter IV, pages 60 and 
61. required a large number 
of cores to produce the bolt- 
holes in each side of the cast- 
ing. To meet this situation, 
eight core-boxes were mount- 
ed on the moulding machine 
shown m Figure 203, which required an operation of three 
hours to produce the rack of cores shown in Figure 204. 

In the core-room of the average foundry producing general 
castings, very little attention has been given to the possibilities 
of producing cores on moulding machines ; yet this vast field 
of possibilities is awaiting the foundryman who will follow the 
lead of those now beginning 
to realize that it is not enough 
to make the saving possible 
on the moulding floor, but 
that this saving should be car- 
ried into the production of 
the core-room. Figure 205 
shows a Roll- Over Jolt 
Moulding Machine used in 




Fig. 205 



the production of large cores. The core boxes shown in the 
background are all used on this one machine in one day. This 
is a Roll-Over Jolt type of moulding machine, which jolt 
rams the core, rolls it over, and draws the box from the core 
by power. On the run-out car may be seen the core that 
was produced in the box shown mounted on the machine. 



CHAPTER XIV 

Foundations for Jolt-Ramming 
Moulding Machines 

In order to intelligently consider the proper foundations 
for modern jolt-ramming machines, it is necessary to review 
briefly some of the machines of earlier types. In many instances 
it was considered necessary, to effectively jolt-ram a mould, to 




Fig. 206. Plain Jolt-Ramming Moulding Machine witli only Suf- 
ficient Foundation to Hold the Machine in Place. The Sand 
may be Filled Around the Machine as the Working Parts 
are Protected. 

have a machine that would produce a heavy blow. This usually 
was accomplished by building the machine with a stroke of 3 
to 4 or even 6 inches in length. This stroke, of course, would 
produce the heavy blow, its action was not unlike the blow of a 
steam hammer. 

In order to control the ground vibrations produced by such 
a machine, it was necessary to provide massive foundations, and 
in many instances the concrete was capped with several layers 
of wood to aid in the absorption of the blow. 



210 



Foundry Moulding Machines and Pattt-rii Equipv.rnt 



The recent rapid development of jolt-ramniing machines 
has practically reversed the early theory of design, as it has 
been determined that it is not the force of the machine blow 
that packs the sand, but that it is packed by the jolting table 
being suddenly or abruptly brought to rest while the sand in 
the flask to be packed continues its downward course, thereby 
producing the pressure which results in the sand packing against 
the pattern or pattern-plate. It is quite evident, therefore, that 




Fig. 207. Foundry Floor View of Jolt-Ramming Power-Stripping 
Moulding Machine with Working Parts Protected. 

if the machine which has been brought suddenly to rest be 
instantly started again on its upward stroke and not allowed to 
pause, an increased pressiu'e of the pattern against the sand 
will result, which causes the sand to lay and not rebound. 

A jolting machine necessary to accomplish this need not 
be miduly massive in its working parts, nor need it have a 
long stroke, 1 to 2 inches usually being sufficient. It should 
have means of ctintroUing the force of the blow of the table 



Foundations for Jolt Ramming Moulding Machines 



211 



Avhen contacting with the anvil base, as it is evident that 
the weiglit of the moving table (or dead load) must not be 
allowed to freely drop and contact with the anvil block, or it 
will produce the unnecessary heavy blow. The up-to-date, 
uiodern jolting machine prevents this heavy blow by providing 

r 




Fig. 208. Same Machine as Fig. 207, Showing 
Simplicity of Foundvitio'i. 

an air cushion under the cylinder sufficient to overcome the 

violent blow caused by the dead load, allowing only sufficient 

blow to accomplish the instant reversal of stroke. 

A machine that accomplishes the foregoing not only will 

ram a good mould in a very short time, but will do so without 

excessive or detrimental vibration in either the machine, pattern 

or foundation. 



Foundry Moulding Machines and Pattern Eijuifn.ent 



'\s we now approach our subject — the machine foundation 
— it is evident that with such a machine the extremely massive 
foundation is not essential and, therefore, our consideration will 
be from the standpoint of economy and accessibility. 

Of first importance is the kind and nature of the soil upon 
which the machine foundation is to be placed. A dry gravel is 
considered the thing next best to solid rock and will safely stand 
a load of 6,000 to 8,000 pounds per square foot. Dry ^and or 




Fig. 209. A Large, 42 x 97-inch, Plain Jolt-Ramming Moulding 
Machine, Showing Section Through Foundation and Pit. 

dry sand and gravel mixed makes a very good foundation base 
and will withstand a load of 4,000 to 8,000 pounds per square 
foot. Clay soils vary widely ; a soft clay will flow in all direc- 
tions even under very light load, and should not be loaded more 
than 3,000 pounds per square foot, while a dry clay will satisfac- 
torily stand a load of 3,000 to 5,000 pounds per square foot. If 
the foundation is to be placed on made ground or fill, provision 
should be made to keep the ground perfectly dry and free from 



Foundations for Jolt Ramming Moulding Machines 



213 



water. With the proper condition existing a satisfactory foun- 
dation can be made, such condition being more desirable than a 
wet or oozy clay soil. When the foundation is placed on clay or 
fill, better results can be obtained by having it cover a large area 
rather than making it of greater depth, unless the fill is of such 
depth that the foundation may be extended through to solid soil. 




Fig. 210. A 64-inch Roll-Over Jolt-Moulding Machine, Showing 
Section Through Foundation. 



It must be remembered that when we place a moulding 
machine in the foundry Ave are actually violating the old estab- 
lished principle of -machine installation and placing it in a 
sand pile instead of an engine room, or other dirt and dust- 
proof room, and yet notwithstanding this extraordinary condi- 
tion, and without giving the machine proper care, many found- 
rymen expect as good results from the machine in the sand pile 
as they do from the machine that was placed in a dust-proof 
room and in charge of an expert mechanic. 



214 



Foundr\ Mouldivji Machines and Pattern Euuipvient 




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Foundations for Jolt Ramming Moulding Machines 



21.") 




Fig. 212. View of Large, 42xl09-inch Roll-Over Jolt-Moulding Machi 




Fig. 213. A 36xl50-inch Roll-Over Jolt-Moulding Machine, Base and 
Foundation Shown in Phantom as it Appears Above Foundry Floor. 



216 



Foundry Moulding, Machines and Pattern Equipment 



The accompanying illustration will demonstrate that it is 
economy to provide a foundation and setting that will give 
ample protection to the machine, by making it impossible for 




Fig. 214. Foundry Floor \iew of 42-inch Klectrically Operated Roll 
Over Jolt-Moulding Machine, Showing Foundations in Phantom. 



sand to collect on the machine or in its moving parts. They also 
will show the advisability of providing ample space around the 
machine so that the mechanic can easily oil, inspect and keep 
the working parts in order, the same as he does the machine 
placed in the engine room. The depth of the space surrounding 



Foundations for Jolt Ramming Moulding Machines 



I'T 




Fig. 215. Same Machine as Fig. 21-4, Showing Section of Foundation. 





Fig. 216. This Photograpli was Taken in the Pit and Shows the Ex- 
cellent Condition of the Base of this Jolt-Ramming Moulding 
Machine and its Freedom from Sand, etc. 



218 



Foundry Moulding Machines and Pattern Equipment 



the machine should be sufficient for a man to stand erect, suit- 
able lighting facilities should be provided and a stairway or 
ladder should lead into the pit. 

The covering of the pit or foundry floor should be made of 
2-inch matched planking and should be fitted tight against the 




Fig. 217. I lUrancc Way into the Foundation Pit of a Jolt-Moulding 

Machine, Showing Steps Leading into the Pit from an 

Adjoining Basement Room. 

machine. The trap door leading into the pit should be hinged 
and of ample size. 

The engineer or architect called upon to design and build 
the foundry of tomorrow will do well to thoroughly consider 
the best method of installing and maintaining the moulding 
machines to be used, placing them in such manner as to insure 
ample protection from dust and grit and making it easy to give 
the machines the care and attention they deserve. 



Foundations for Jolt Rammiw^ Moulding Machines 



219 




F'ig. 218. \iew of Jolt-Raniniing Moulding Machine, Taken in the 
Pit, Showing Construction of the Pier. 




Fig. 219. View Showing Several Jolt-Ramming Moulding Machine 
Foundations with Piers Built on the Basement Floor. 



220 



foundry Moulding Machines and Pattern Equipment 



The author's idea of a foundry that will best meet these 
practical requirements is set forth in l-'igure 220. This illustra- 
ti(in shows the cross-section of a proi)Osed foundry, havinj^ 
a tunnel or basement extendini'- the full length of the mouldinef 



^ 




Fig. 220. Cross-Section of the Proposed Foundry, Showing Tunnel 
for Machine Foundations. 



floor. The floor of this tunnel or basement should be at least 
7 feet below the ceiling and the width should be sufficient to 
allow a clear passageway on one side of the machines ; the piers 
for the machine foundations can be placed at any time and to 
suit anv condition. 



foundry Moulding Machines and Pattern Equipment 



Index 



A 



Airplane Castings 78 

Alloys for Match Plates 184 

Aluminum Crank Cases 109 

Aluminum Hasks 110, 111 

Aluminum Foundries 107 

Armored Truck Castings. . .79, 99, 100 

Automobile Castings 

74, 75, 76, 77, 9f), 97, 98 

Floors of 85-91 

Automotive Industry 

Core Making In 203 

State of 166, 203 



B 



Bedding on the Bottom Board . 19 

Bottom Boards 198 

Bottom Strike Machines 117 

Brass Foundries 107 

Butting off 

Definition 15 

Speed of 15 

Variation 15 



Care of Machines 120 

Castings 

Machine moulded 9^1 

Center Lines on Pattern 72 

Changing Patterns 71 

Clamping Bottom Boards 54 

Clay Wash for Gaggers 13 

Competitive Spirit 71, 72 

Construction 

Pattern Draw on Roll Over 48 

Patterns 162 

Plain Jolt Machine 117 

Roll Over Machines 47 

Continuous Pouring 107 

Cope on Roll Over Machines 71 

Cope on Stripper Machines .... 71 , 149 

Core 

Assembly 204 

Covering 25, 26 

Green Sand 206 

Inserted 24, 25 

Production 203 

Ram-up 22, 25 

Setting Jigs 205 

Core Machines 69, 1 1 1 , 203-208 

Core Print 23 

Crane Equipment 5*) 



Crank Cases 

Floor of 85 

Production of 113 

D 

Deflection of 

Leveling Tables 49 

Patterns 163 

Roll Over Tables 49 

Density of Ramming 160 

Design of 

Flasks 163, 189 

Jolt Machines 37, 117 

Patterns 161 

Squeezers 139 

Vibrator 21 

Development of 

Plain Jolt Machine 115 

Squeezers 133 

Diagram of Vibrator 21 



Equipment 

Crane 59 

Flask 7, 188-202 

Pattern 161-187 

F 

Facing Sand 52 

Flask 

Bars 121, 195 

Construction 198 

Design 121, 163, 189 

Drawings 191 

Jigs 195 

Pins 195, 197 

Flask Equipment 188-202 

Flasks 

Aluminum 110, 111 

Cut 164 

Grey Iron 191 

Rectangular 190 

Snap 201 

Steel 199 

Floors, views of 85, 91, 104, 105 

Follow Board 143, 173, 174 

Form for Pouring Basin 27, 28 



Gaggers 

Use of 13 

Clav Wash for 13 



Index 



223 



Gate Pattern \Xi 

Use of 147 

Gate, Swirl 27 

Gating 27 

(jcnerator Castings. . . .122, 123, 124 

Gravity, center of, in rolling over 45 

Green Sand Cores 206 

Green Sand Match 133 

H 

Hand Ramming 

Difficulties of 31 

Requirements of 31 

1 land Roll Over on Squeezers 136 

Hard Sand Match 133, 173, 174 

H>draulic Machinery Castings .... 125 

I 

Ideal Moulding Machine 117 

Impact of Machine 34, 41 

Inspection of Machines 120 

Indicator Tests 34 

Cards 35-36 

When used 38 

Inserted Cores 24, 25 

Inverted "\'" Construction 139 

J 

Jobbing Foundry Methods 168 

Jolt Machine 

Design 37 

Plain 114-131 

Time sa\ed b}' 33 

Jolt Ramming 

Cushioning of 35 

How accomplished 32 

Length of Stroke 32 

On Roll Over Machine 41 

Rate of Blows 32 

Recess 134 

Theory of 31 

Time required 32 

Jolt Squeezer Machine 

Advantages of 138 

Construction 134 

Design of 139 

Operat'on 135 

Production on 139 

Jolt Squeezer Stripper Machines. . 

Advantages of 155 

Operation of 159 

Speed of 155 

Jolt Stripper Machines 148-163 

Functions of 149 

Used for Copes 149 



L 

Le\'eling car 

Deflection in 49 

Design of 49 

Use of 47 

Libertv Engine 107 

Loose Pieces 18, 23 

M 

Machinery Castings. . . .06, 67, ()S, 80 

Maintenance of Machmes 120 

Marine Castings. .. .63, 64, 65, 81 
82, 83, 84 

Match Plates 

Alloys for 184 

Construction of 176 

Use of 145 

Materials for Patterns 162 

Metal Patterns and Plates 164 

Method of 

Drawing Pattern 49 

Using Upset 13 

Method of Making Moulds 

On Floor 52 

On Jolt Squeezer 20 

On Plain Jolt 2, 3 

On Roll Over Machines 4, 5 

On Squeezer Alachines 7, 12 

On Stripper Machines. . . .5, 8, 10 

Moulds 

Large .". 59 

Medium 71 

Small 93 

Mounting Patterns 161 



Oil Sand Match (See Hard Sand 
Match) 

Operation of Making Moulds on 

Floor 52 

Jolt Squeezer Machine 7, 20 

Jolt Squeezer Stripper Mach. .5, 10 
159 

Jolt Stripper Machine 5, 8 

Plain Jolt Machine 2, 3 

Plain Squeezer Machine 7, 12 

Roll Over Machine 4,5, 52 

Operation of 

Jolt Squeezer Machine 135 

Pattern Drawing 48 

Roll Over Machine 43-47 

Squeezer Machine 135 

Operations of Making Mould 52 

Overhanging Projections 23 



224 



Foundry Moulding Machines and Pattern Equipment 



Output of 

LarKC Roll Over Machine .")9 

Patching Moulds ... .").j 

Pattern Design IGl 

Pattern Drawing 

.\ccurac\' of Parts for 4'.) 

Method 'of 49 

On Roll Over Machines 48, .")1 

Time saved by 48 

Pattern Equipment 161 , 187 

Pattern Materials lOi 

Pattern Mounting 

Cost of II 

Skill required for !), 165 

Pattern Plates, use of ')'2, llo 

Patterns for 

Flasks 19S 

Plain Jolt Machines 114-131 

Squeezer Machines 133-1."57. 173 

Stripper Machines ISO 

Patterns, Metal 164 

Pins, Stripping of 151 

Plain Jolt Machine. . . 114-131 

Plain Squeezer 

Operation of 137 

Patterns for .137 

Pop Valve 136 

Portable Machines 94, 107 

Production 

On Plain Jolt Machines 115, 121 

On Roll Over Machines . .61 et seq. 

On Squeezer Machines 139 

Q 

Quality- of Castings . . 42 

Quantity of Castings ... 116 

R 

Railway Castings 62 

Ramming 

See Hand Ramming 
Also Jolt Ramming 

Ram off 134 

Ramming Requirements 33 

Ramming. Uniformity of 33, 38 

Ram-up Core, Uses of 25 

Rapping of Pattern 19 

Recess, jolting of 134 

Remo\ing Mould from Machine . .50-51 

Rigiditv of Patterns 163 

Roll Over Jolt Machin-.-s 

For Cores 69, 208 

Functions of 41 

Illustration of typical . . 40, 5S, 92 



Large 59 

Medium 71 

Portable 94 

Production on 72 

Small 93 

Use in Brass and Aluminum. . . . 107 

Roll Over Operation 43 

Construction 47, 48 

Principles 43 

Speed of 93 

Time saved by 43 

Rough Castings, cause of 31 



Sand 

Clearance 163 

Moulding 29 

Packing of 32 

Spreading of 15, 16 

Sand Straddlers 139 

Savings in Shipbuilding Industry. . 

83, 84 

Shell Patterns 172 

Shipbuilding Industry 83, 84 

Slicking 55 

Snap Flasks 201 

Correct Proportions 141 

Split Pattern Alachine 135 

Sprue 137 

Squeezer Machines 

Design of 139 

Development 133 

Jolt Squeezer 133 

Operations of 135 

Patterns for 133, 173 

Plain 133 

Production on 139 

Steel Flasks 199 

Striking Off 17, 53 

Stripping Plates 

Gates on 151 

Mounting of 150 

Need for 1 50 

Pins on 151 

Swirl Gate 27 

Symmetrical Patterns 72 

T 

Tabulations, Shipbuilding Indus- 
try 83, 84 

Tests on Moulding Sand 29 

Theory of Jolt Ramming 31 

Time saved bv Jolt Machine 33 

Bv jolting.' 42 

By "Rolling Over . 43 



Index 



225 



Top Strike Machine 117 

Types of Machines 7 

Typical 

'Mould 1 

Roil Over Alachines 40, oS, 70 

Tunnel Segment Castings (50, 61 

Tunnel Segment Cores 208 

U 

Universal Pattern Plate 168 

Uniformity of Castings .">, 42, 156 

Uniformity of Ramming 33, 38 

Upset, use of 13 

Use of Gaggers 13 

Use of Gated Patterns 147 

Use of Vibrator 137 

Use of Vibrator Frame 145 

Uses of ... 

Inserted Cores 25 

Ram-up Cores 25 



\ 

\'ariations in 

Butting off 15 

Size of Castings . 156 

Weight of Castings 51, 156 

\ ibration in machines 118 

\ibrator 

Diagram of 21 

Use on Squeezers 137 

\'ibrator Frames 

Construction of 175 

Use of . . .' 1 45 

W 

Weight of Castings 51 

Wood Patterns 166 

Wood Pattern Plates . . 166 

Wood Flasks 189 



360 90 







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BINDERY INC. 

^ AUG 90 

N. MANCHESTER, 
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